Dodge - Ram 1500 4wd - Workshop Manual - 2005 - 2005

Factory Workshop Manual Make Dodge Model Ram 1500 4wd Engine and year Truck V8-5.7L VIN D (2005) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation Alarm Module: Description and Operation The Sentry Key Immobilizer Module (SKIM) (1) is the primary component of the Sentry Key Immobilizer System (SKIS). This module contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKIM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKIM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKIM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. The Sentry Key Immobilizer Module (SKIM) transmits Radio Frequency (RF) signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM) for gasoline engines or the Engine Control Module (ECM) for diesel engines, the ElectroMechanical Instrument Cluster (EMIC) and/or a diagnostic scan tool. The SKIM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKIM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM or ECM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the transponder in the ignition key. The SKIM then listens for a return RF signal from the transponder. If the SKIM receives an RF signal with a valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM/ECM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM or ECM is an invalid key. Therefore, if no message is received from the SKIM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 7 The SKIM also sends electronic messages to the EMIC which control the VTSS indicator. The SKIM sends messages to the EMIC to turn the indicator on for about three seconds when the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the indicator off for a duration of about one second. Then the SKIM sends messages to turn the indicator on or off based upon the results of the SKIS self-tests. If the VTSS indicator comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the On position, it sends messages to flash the VTSS indicator. The SKIM can also send messages to flash the indicator and to generate a single audible chime whenever the Customer Learn programming mode is being utilized. The SKIS will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. For diagnosis or initialization of the SKIM and the PCM/ECM, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 8 Alarm Module: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 9 8. Disconnect the wire harness connector (2) from the Sentry Key Immobilizer Module (SKIM) (1). 9. Remove the screw (3) that secures the SKIM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKIM. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 10 1. Position the Sentry Key Immobilizer Module (SKIM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKIM to the steering column housing. Tighten the screw to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the SKIM (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 11 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.) 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.) 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 10. Reconnect the battery negative cable. NOTE: If the SKIM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 15 Module-Sentry Key Immobilizer (SKIM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 16 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 17 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 18 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Right Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 22 Voice Activation Module: Diagrams Module-Hands Free C1 Module-Hands Free C2 Module-Hands Free C3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 23 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation RELAY PACK DESCRIPTION Relay Pack Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. OPERATION In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay Winch Relay: Service and Repair Winch Relay RELAY REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 29 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 30 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). 3. Tighten the nuts to 3 N.m (25 in.lbs.) 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 N.m (85 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 31 6. Install the relay pack (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 32 Winch Relay: Service and Repair Winch Relay Pack RELAY PACK REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 33 3. Remove the nut and disconnect the red battery positive cable (1). NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 34 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 N.m (25 in.lbs.). 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 N.m (85 in.lbs.). 5. Install the relay pack cover (1) and install the three screws (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 35 6. Install the winch assembly (2). 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 40 Heated Mirror Relay: Description and Operation The heated mirror relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The heated mirror relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the outside rear view mirror heating grids. The heated mirror relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The heated mirror relay is located in the IPM in the engine compartment. The ISO-standard heated mirror relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the outside rear view mirror heating grids. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the outside rear view mirror heating grids. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The heated mirror relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the heated mirror relay include: - Terminal (30) receives fused battery current at all times. - Terminal (86) receives a ground through the defogger relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (85) receives fused battery current through an ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the heated outside rear view mirror grids through the heated mirror relay output circuit only when the heated mirror relay coil is energized. - Terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the heated mirror relay coil is de-energized. The heated mirror relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete heated mirror system wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 41 Heated Mirror Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for heated mirror relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the heated mirror relay from the IPM. INSTALLATION 1. Position the heated mirror relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the heated mirror relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 45 Module-Sentry Key Immobilizer (SKIM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 46 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 47 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 48 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42°C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 55 Power Seat Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 56 Power Seat Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Module-Heated Seats Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 60 Seat Heater Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 61 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to testing for flashing LED diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to testing for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12 v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 62 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 70 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 71 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 72 Electronic Brake Control Module: Diagrams Module-Antilock Brakes C1 Module-Antilock Brakes C2 (AWAL) Module-Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 73 Electronic Brake Control Module: Description and Operation The Antilock Brake Module (ABM) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a DRB III. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 74 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a DRB 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 N.m (16 in.lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 82 Compressor Clutch Relay: Description and Operation The A/C clutch relay (1) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay The A/C clutch relay is located in the integrated power module (IPM) in the engine compartment. The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input from the powertrain control module (PCM) or engine control module (ECM) (depending on engine application), to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (86) receives a ground input from the PCM/ECM through the A/C clutch relay control circuit only when the PCM/ECM electronically pulls the circuit to ground. - The coil battery terminal (85) receives a battery current input from PTC 1 in the IPM through a fused ignition switch output (run) circuit only when the ignition switch is in the On position. - The normally open terminal (87) provides a battery current output to the A/C clutch coil through the A/C clutch relay output circuit only when the A/C clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C clutch relay coil is de-energized. The A/C clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard micro-relay and for complete HVAC wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 83 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2). NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for A/C clutch relay location. 3. Remove the A/C clutch relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for A/C clutch relay location. 1. Position the A/C clutch relay into the receptacle of the integrated power module (IPM) (2). 2. Align the A/C clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 91 Fog/Driving Lamp Relay: Description and Operation The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The front fog lamp relay is located in the Power Distribution Center (PDC)See: Relays and Modules - Power and Ground Distribution/Relay Box Applications and ID in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the front fog lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the front fog lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the front fog lamps through a fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 95 Parking Lamp Relay: Description and Operation The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The park lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the park lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact point away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the park lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the park lamps through a park lamp relay output circuit and provides battery voltage to the park lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 100 Battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 101 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 102 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 103 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 104 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 105 Module-Integrated Power C5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 106 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 109 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 110 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 113 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 114 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 115 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 120 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 121 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 125 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 126 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 127 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 128 Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 129 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 130 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 131 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 132 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation Body Control Module: Description and Operation The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 140 Body Control Module: Symptom Related Diagnostic Procedures Air Bag System AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems Diagnostic Test 1. AIRBAG WARNING INDICATOR ON WITHOUT ACTIVE TROUBLE CODES NOTE: Ensure the battery is fully charged. Turn the ignition on. Make sure that all active DTC's have been repaired before performing this procedure. With the DRBIII(R) read the WARNING LAMP STATES. Q: With no active DTCs, Does the LAMP REQ by ACM monitor show ON? YES: Go To 2 NO: Perform ORC VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test 2. REPLACE THE ORC WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER (ORC) IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. NOTE: When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected. Repair Replace the ORC. Perform ORC VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test NOTE: When reconnecting Airbag system components, the ignition must be turned off and the battery must be disconnected. Audio System Audio System Diagnosis Table Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 141 Audio System Diagnosis Table Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 142 Audio System Diagnosis Table Part 3 Of 3 Any diagnosis of the Audio system should begin with the use of a scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Chime Inoperative CHIME INOPERATIVE POSSIBLE CAUSES - Cluster Diagnostic Test 1. ACTUATE THE CHIME WITH THE DRBIII Turn the ignition on. Close the doors. With the DRBIII(R) select: Electro/Mech Cluster and actuate the Chime. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 143 Q: Does the chime sound when actuated by the DRBIII(R)? YES: If the chime operates as it should, check for other reasons that the chime is being inoperative. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Sounds With Drivers Door Open and Key Removed From Ignition CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 144 Chime Sounds With Driver Door Open Key Removed POSSIBLE CAUSES - Key-in IGN SW status - Ignition switch shorted - (G26) Key-in ignition sw sense short to ground - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 145 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: Ensure the exterior lamps turn on and off properly and are off before continuing this test. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Remove the key from the ignition switch. Q: Does the DRBIII(R) show Key-In IGN OPEN? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. KEY-IN IGN SWITCH SHORTED Disconnect the Ignition Switch connector. Q: Did the chime turn off? YES: Check the Ignition Lock Cylinder for damage. If OK replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 146 3. (G26) KEY-IN IGNITION SWITCH SENSE WIRE SHORT TO GROUND Turn ignition off. Disconnect the Ignition Switch connector. Disconnect the Cluster C3 connector. Measure the resistance of the (G26) Key-in Ignition Switch Sense circuit to ground at the Ignition Switch connector. Q: Is the resistance below 100.0 ohms? YES: Repair the (G26) Key-In Ignition Switch Sense wire for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Warning System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 147 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 148 WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired chime warning system inputs to the ElectroMechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and methods. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Programmable Communications Interface (PCI) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Key In Ignition and Drivers Door Open Chime Inoperative KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 149 Key In Ignition And Driver's Door Open Chime Inoperative POSSIBLE CAUSES - (Z42) Ground open - (G26) Key-in ignition switch open - Ignition switch - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 150 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: The driver's door ajar switch must be operational for the result of this test to be valid. Ensure that the Key is still in the Ignition Switch. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Q: Does the DRBIII(R) show Key-In IGN CLOSED? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. IGNITION SWITCH GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch connector. Turn all lights off. Measure the resistance between ground and the (Z42) Ground circuit in the ignition switch harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 151 NO: Repair the (Z42) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. IGNITION SWITCH OPEN Connect the ignition switch connector if disconnected. Turn ignition on. With the ignition switch connector connected, back jumper the (G26) Key-In Ignition Switch Sense circuit to ground at the ignition switch connector. With the DRBIII(R), enter Instrument Cluster Input/Outputs and observe the Key-In IGN SW status. Q: Does the DRBIII display Key-In IGN SW: Closed? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. KEY-IN IGNITION SWITCH SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch harness connector. Disconnect the Cluster C3 harness connector. Measure the resistance of the (G26) Key-In Ignition Switch Sense circuit between the ignition switch connector and the Instrument Cluster C3 connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 152 Q: Is the resistance below 5.0 ohms? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G26) Key-In Ignition Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Vehicle Speed Warning Chime Problem VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in cluster - Cluster Diagnostic Test 1. WITH THE DRBIII CHECK THE COUNTRY CODE SETTING NOTE: The high speed warning chime is for Gulf Coast Countries only. Turn the ignition on. With the DRBIII(R) in Miscellaneous check the Cluster country code setting. Q: Is the country code incorrect? YES: Program the correct country code. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Heater Control Illumination Inoperative A/C HEATER CONTROL ILLUMINATION INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 153 A/C Heater Control Illumination Inoperative POSSIBLE CAUSES - Faults present in the cluster (MIC) - (E16) Panel lamps driver circuit open - Bulb(s) - filament open (single-zone HVAC module only) - Cluster (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 154 - A/C Heater control Diagnostic Test 1. CHECK FOR DTCs IN THE CLUSTER (MIC) Turn the ignition on. With the DRBIII(R), read Cluster DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. TEST (E16) PANEL LAMPS DRIVER CIRCUIT USING A TEST LIGHT Turn the Headlamp switch on. Rotate the Cargo Dome switch to the full brightness setting. CAUTION: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (E16) Panel Lamps Driver circuit in the A/C Heater Control C1 harness connector. Q: Does the test light illuminate brightly? YES: (Dual-Zone Systems) Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: (Single-Zone Systems) Go To 3 NO: Go To 4 3. INSPECT THE INOPERATIVE BULB(S) Turn the ignition off. Remove the inoperative bulb(s) from the A/C Heater Control. NOTE: If necessary, hold the bulb in front of a lamp to see the filament. Inspect the bulb(s). Q: Is each inoperative bulb Ok? YES: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the inoperative bulb(s). Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 155 Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. CHECK (E16) PANEL LAMPS DRIVER CIRCUIT FOR AN OPEN Disconnect the A/C Heater Control C1 harness connector. Disconnect the Cluster C1 harness connector. Measure the resistance of the (E16) Panel Lamps Driver circuit between the A/C Heater Control C1 harness connector and the Cluster C1 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (E16) Panel Lamps Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Flashing A/C STATUS INDICATOR FLASHING Theory of Operation Running the AC Cooldown test will cause the A/C status indicator to flash. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. When the A/C status indicator is flashing, it will not indicate A/C operating status. However, the A/C mode switch will continue to function normally. For vehicles equipped with EBL, when the A/C status indicator is flashing, the EBL status indicator will not function. However, the EBL mode switch will continue to function normally. POSSIBLE CAUSES - A/C Cooldown test failed 1. PERFORM THE A/C COOLDOWN TEST NOTE: The following are prerequisites of the Cooldown Test. Verify each of the following before running the test: - Verify that no Evaporator Temperature Sensor related DTCs are not active. If active, diagnose and repair the DTC before proceeding. - Verify that the refrigerant system has an adequate charge. Check and repair as necessary before proceeding. - Verify that the blower motor operates correctly in all speeds. Diagnose and repair all blower related faults before proceeding. - Verify that the work area ambient temperature is above 21.1° C (70° F) before proceeding. Move the vehicle to a warmer work area if necessary. - Verify that the evaporator temperature is above 12.7° C (55° F) before proceeding. - Verify that the Mode Select control is set to the panel position. - Verify that the A/C compressor is not running. If the compressor is running, turn the A/C off and allow the evaporator to warm up before proceeding. Start the engine. Turn the Blower control to the high speed position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 156 With the DRBIII(R) in HVAC, select System Tests and then select AC Cooldown test. Allow one minute for the test to complete. One or more status messages will display on the DRBIII(R) after running the AC Cooldown Test. These messages will clear after paging back out of this test function. Therefore, it is important to note all messages before doing so. Q: Does the DRBIII(R) display a status message that indicates a fault has occurred? Yes, Blower Not On High Diagnose and repair the fault. Refer to Blower Not On High for the diagnostic test procedure. Yes, Cooldown Test Sensor Failure Diagnose and repair the fault. Refer to Cooldown Test Sensor Failure for the diagnostic test procedure. Yes, Cooldown Time Excessive Fault Diagnose and repair the fault. Refer to Cooldown Time Excessive Fault for the diagnostic test procedure. Yes, Cooldown Test Too Cold To Start Diagnose and repair the fault. Refer to Cooldown Test Too Cold To Start for the diagnostic test procedure. NO: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW A/C STATUS INDICATOR WILL NOT ILLUMINATE - A/C HEATER CONTROL WITHOUT EBL SW Theory of Operation Failing recalibration will prevent the A/C status indicator from operating but still allows the A/C mode switch to function normally. This test verifies if the status indicator is inoperable due to either a recalibration failure or a fault with the status indicator. POSSIBLE CAUSES - HVAC door recalibration failed - A/C Heater control Diagnostic Test 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Failed? YES: Diagnose and repair the fault(s). NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Dual-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 157 Actuator Circuit Test Diagnostics (Dual-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 158 messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test fault message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 159 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 160 5. RUN THE ACTUATOR CIRCUIT TEST Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 161 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 162 YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 163 Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C29) Mode Door 2 Driver circuit and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C33) Passenger Blend Door Driver circuit for a short to the (C29) Mode Door 2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 12 12. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 164 Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 13 NO: Go To 14 13. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 165 14. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Single-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 166 Actuator Circuit Test Diagnostics (Single-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 167 shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 168 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 169 5. RUN THE ACTUATOR CIRCUIT TEST Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 170 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 171 NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C29) Mode Door 2 Driver circuit for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 172 Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 12 NO: Go To 13 12. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 173 YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 13. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Dual-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 174 Blend/Mode/Recirc Door Operation Improper (Dual-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 175 - Door(s) bound up, warped, worn, damaged - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Passenger Blend Door Function Test Go To 6 Driver Blend Door Function Test Go To 7 Recirculation Door Function Test Go To 8 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 176 Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK PASSENGER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Passenger Blend control to the full hot position. Move the Passenger Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the passenger's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Passenger Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK DRIVER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Driver Blend control to the full hot position. Move the Driver Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the driver's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Driver Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Single-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 177 Blend/Mode/Recirc Door Operation Improper (Single-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open - Door(s) bound up, warped, worn, damaged Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 178 - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Blend Door Function Test Go To 6 Recirculation Door Function Test Go To 7 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 179 YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Blend control to the full hot position. Move the Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Motor Inoperative (Except SRT10) BLOWER MOTOR INOPERATIVE (EXCEPT SRT10) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 180 Blower Motor Inoperative (Except SRT10) POSSIBLE CAUSES - (C7) Blower motor feed circuit shorted to ground - (A970) Fused B(+) circuit shorted to ground - (C70) Blower motor high driver circuit open - (Z134) Ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 181 - (C7) Blower motor feed circuit open - (A970) Fused B(+) circuit open - IPM fuse #4 open - Blower motor - Ignition switch - A/C heater control Diagnostic Test 1. CHECK THE FUSE Turn the ignition off. Remove and inspect IPM Fuse #4. Q: Is the fuse open? YES: Replace IPM Fuse #4 and Go To 2. NO: Reinstall IPM Fuse #4 and Go To 5. 2. CHECK BLOWER MOTOR OPERATION Turn the ignition on. Turn the blower on and operate it in all speeds and modes. Q: Does the blower motor operate properly without blowing the fuse? YES: Check the (C7) Blower Motor Feed circuit and the (A970) Fused B(+) circuit for an intermittent short to ground. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 182 Turn the ignition off. Disconnect the Blower Motor harness connector. Measure the resistance of the (C7) Blower Motor Feed circuit between ground and the Blower Motor harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C7) Blower Motor Feed circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (A970) FUSED B(+) CIRCUIT FOR A SHORT TO GROUND Disconnect the Ignition Switch harness connector. Measure the resistance of the (A970) Fused B(+) circuit between ground and the Ignition Switch harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (A970) Fused B(+) circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor and fuse. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 183 Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Blower Motor harness connector. Q: Does the test light illuminate brightly? YES: Go To 6 NO: Go To 9 6. CHECK BLOWER MOTOR OPERATION BY BYPASSING THE A/C HEATER CONTROL Turn the ignition off. Connect a jumper wire between ground and the (C70) Blower Motor High Driver circuit in the Blower Motor harness connector. Turn the ignition on. Q: Does the blower motor run at high speed? YES: Go To 7 NO: Replace the Blower Motor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 184 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor harness connector. Measure the resistance of the (C70) Blower Motor High Driver circuit between the A/C Heater Control C2 harness connector and the Blower Motor harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 8 NO: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (Z134) GROUND CIRCUIT FOR AN OPEN Measure the resistance of the (Z134) Ground circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the A/C Heater Control. NO: Repair the (Z134) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 185 NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Repair the (C7) Blower Motor Feed circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (A970) FUSED B(+) CIRCUIT FOR AN OPEN NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (A970) Fused B(+) circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (A970) Fused B(+) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 186 Blower Speed Does Not Correspond With Control Setting BLOWER SPEED DOES NOT CORRESPOND WITH CONTROL SETTING Blower Speed Does Not Correspond With Control Setting POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 187 - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to ground - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to voltage - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted together - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit open - Blower motor resistor block open - A/C heater control Diagnostic Test 1. CHECK IF THE BLOWER MOTOR RUNS WITH THE BLOWER CONTROL IN THE OFF POSITION Turn the Blower control to the Off position. Turn the ignition on. Q: Does the blower motor run? YES: Go To 2 NO: Go To 3 2. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms on any of the circuits? YES: Repair all circuits with a resistance below 10K ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 188 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Does the test light illuminate brightly on each circuit? YES: Go To 4 NO: Go To 8 4. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the voltage of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is there voltage present on any of the circuits? YES: Repair all circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 189 NO: GO TO 5 5. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR A SHORT TO THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C71) Blower Motor Low Driver circuit and the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C71) Blower Motor Low Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C71) Blower Motor Low Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR A SHORT TO THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C73) Blower Motor M2 Driver circuit and the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C73) Blower Motor M2 Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C73) Blower Motor M2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR A SHORT TO THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 190 Measure the resistance between the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C72) Blower Motor M1 Driver circuit for a short to the (C70) Blower Motor High Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 9 NO: Repair the (C71) Blower Motor Low Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 191 Measure the resistance of the (C73) Blower Motor M2 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 10 NO: Repair the (C73) Blower Motor M2 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR AN OPEN Measure the resistance of the (C72) Blower Motor M1 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 11 NO: Repair the (C72) Blower Motor M1 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 11. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 192 Measure the resistance of the (C70) Blower Motor High Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor Resistor Block. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test EBL Status Indicator Flashing EBL STATUS INDICATOR FLASHING Theory of Operation Running the HVAC Door Recalibration will cause the EBL status indicator to flash. If recalibration fails, the status indicator will continue to flash until either the system passes recalibration or the ignition key is cycled. When the EBL status indicator is flashing, it will not indicate EBL operating status. However, the EBL mode switch will continue to function normally. When the EBL status indicator is flashing, the A/C status indicator will not function. However, the A/C mode switch will continue to function normally. POSSIBLE CAUSES - HVAC door recalibration failed 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Passed? YES: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Diagnose and repair the fault(s). Horn HORNS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 193 Horns Inoperative POSSIBLE CAUSES - DTC present - Fuse #45 - Horns - Horn ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 194 - Horn relay output circuit open - Horn switch - Horn switch ground - Clockspring - Horn switch sense open - Integrated power module - Instrument cluster - Front control module Diagnostic Test 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to symptom list. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. ACTUATE HORN RELAY With the DRBIII(R), actuate the Horn Relay. Q: Do the horns operate? YES: Go To 3 NO: Go To 7 3. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch. Measure the resistance of the Horn Switch ground circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the horn switch ground as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch connector. WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the Horn switch connector and ground. Q: Did the horns sound? YES: Replace the horn switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CLOCKSPRING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 195 Turn the ignition off. Disconnect the clockspring C1 connector. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the clockspring connector and ground. Q: Did the horns sound? YES: Replace the clockspring. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. HORN SWITCH SENSE Turn the ignition off. Disconnect the clockspring C1 connector. Disconnect the Instrument Cluster C3 connector. NOTE: Check connectors - Clean/repair as necessary. Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Instrument Cluster C3 connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Horn Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 196 Tests/Body Verification Test 7. CHECK FUSE #45 Turn the ignition off. Using a 12-volt test light connected to ground, check the Horn fuse #45 in the IPM. Q: Is the fuse open? YES: Replace the fuse. Check for a short to ground in the Horn Relay Output circuit from the IPM to the horns. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. HORN RELAY OUTPUT Disconnect a horn connector. With the DRBIII(R), actuate the Horn Relay. Using a 12-volt test light connected to ground, check the Horn Relay Output circuit. Q: Does the test light illuminate brightly? YES: Go To 9 NO: Go To 10 9. HORN GROUND CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 197 Turn the ignition off. Disconnect the Horn connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit in the horn connector. Q: Does the test light illuminate brightly? YES: Replace the Horns. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. HORN RELAY OUTPUT CIRCUIT OPEN Gain access to the IPM C1 connector. Using a 12-volt test light connected to ground, back probe the Horn Relay Output circuit in the IPM C1 connector. Turn the ignition on. With the DRBIII(R), the actuate the horn relay. Q: Does the test light illuminate brightly? YES: Repair the Horn Relay Output circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 198 11. INTEGRATED POWER MODULE Turn the ignition off. Remove the Front Control Module from the Integrated Power Module. NOTE: - Check connectors - Clean/repair as necessary. - The test light is still connected to the C1 connector. Momentarily jumper the Horn Relay Control circuit to ground at the FCM connector. Q: Does the test light illuminate brightly? YES: Replace the Front Control Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Integrated Power Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test All Gauges Inoperative ALL GAUGES INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 199 All Gauges Inoperative POSSIBLE CAUSES - No response - PCI BUS - No response - PCI BUS - powertrain control module - PCI BUS - instrument cluster - (F21) Fused ignition switch output (run/start) circuit short to ground - (F1) Fused ignition switch output (off/run/start) circuit short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 200 - (F21) Fused ignition switch output (run/start) circuit open - (F1) Fused ignition switch output (off/run/start) circuit open - (Z18) Instrument cluster ground circuit for an open - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS NOTE: Diagnose and repair any MIC, PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test. Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), select Body, MIC, SYSTEM TESTS, PCM Monitor. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PCI BUS - INSTRUMENT CLUSTER Turn the ignition on. With the DRBIII(R), select Body, MIC, MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Inspect the #20 Fuse in the PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 201 If the fuse is open, replace with proper rated fuse. Turn the ignition on for one minute. Turn the ignition off. Inspect the #20 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F21) Fused Ignition Switch Output (Unlock/Run) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. If the fuse is open, replace with the proper rated fuse. Turn the ignition on for 1 minute. Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F1) Fused Ignition Switch Output (Run/Start) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 202 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F1) Fused Ignition Switch Output (Off/Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F1) Fused Ignition Switch Output (Off/Run/ Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 203 Measure the resistance between ground and the (Z18) Instrument Cluster Ground circuit. Q: Is the resistance below 5.0 ohms? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z18) Instrument Cluster Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Any PCI Indicator Inoperative ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - Indicator message not received - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - INSTRUMENT CLUSTER With the DRBIII(R), select MIC, then MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE INSTRUMENT CLUSTER. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. NO RESPONSE - PCI BUS With the DRBIII(R), select Body, MIC, MONITORS, PCI BUS MONITORS. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE POWERTRAIN CONTROL MODULE. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. INDICATOR MESSAGE NOT RECEIVED NOTE: Diagnose and repair any PCM or BCM DTCs before proceeding with this test. Perform the Instrument Cluster Self Test. Depress and hold the Trip Odometer button while turning the ignition from the off to the on position. Observe the indicator in question. Q: Did the indicator illuminate? YES: Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 204 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Always On BRAKE WARNING INDICATOR ALWAYS ON Brake Warning Indicator Always On Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 205 POSSIBLE CAUSES - (B20) Brake fluid level sensor sense circuit short to ground - (B25) Park brake switch sense circuit short to ground - Brake fluid level sensor - Park brake switch - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. BRAKE FLUID LEVEL SENSOR NOTE: Diagnose and repair any MIC, Brake, or Communication DTCs before proceeding with this test. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance of the Brake Fluid Level Sensor between pin 1 and pin 2. Q: Does the resistance measure less than 900 ohms? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 206 Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance between ground and the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PARK BRAKE SWITCH Turn the ignition off. Disconnect the Park Brake Switch harness connector. Turn the ignition on. Observe the Brake warning indicator. Q: Did the Brake warning indicator illuminate briefly and then turn off? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 207 4. (B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (B25) Park Brake Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. ANTI-LOCK BRAKES MODULE Turn the ignition off. Reconnect any harness connector(s) that were previously disconnected. Turn the ignition on. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Inoperative BRAKE WARNING INDICATOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 208 Brake Warning Indicator Inoperative POSSIBLE CAUSES - (Z420) Brake fluid level sensor ground circuit open - (B25) Park brake switch sense circuit open - (B20) Brake fluid level sense circuit open - Park brake switch - Brake fluid level sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 209 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. FAULT LOCATION NOTE: Diagnose and repair any MIC, ABS, or Communication DTCs before proceeding with this test. Q: Is the Brake warning indicator only inoperative using the Park Brake? YES: Go To 2 NO: Go To 4 2. PARK BRAKE SWITCH Disconnect the Park Brake Switch harness connector. Connect a jumper wire between the (B25) Park Brake Switch Sense circuit and ground. Turn the ignition on. Observe the BRAKE indicator. Q: Did the BRAKE indicator illuminate? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 210 Turn the ignition off. Disconnect the (B25) Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (B25) Park Brake Switch Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. BRAKE FLUID LEVEL SENSOR Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Q: Does the Brake warning indicator illuminate? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 211 5. (Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance between ground and the (Z420) Brake Fluid Level Sensor Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z420) Brake Fluid Level Sensor Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. (B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance of the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 212 Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Anti-lock Brakes Module harness connector. Connect a jumper wire between the (B25) Brake Fluid Level Sensor Sense circuit and ground. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Fuel Gauge Inaccurate FUEL GAUGE INACCURATE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 213 Fuel Gauge Inaccurate POSSIBLE CAUSES - Fuel level sensor wiring - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 214 1. DTC PRESENT NOTE: Diagnose and repair any PCI Bus problems before proceeding with this test. Turn the ignition on. With the DRBIII(R), read the PCM DTCs. Q: Does the DRBIII(R) display any Fuel Level Sensor related DTC? YES: Refer to the Powertrain Diagnostic Information for the related symptom(s). Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test as follows: Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the Fuel Gauge during the Self Test. The Fuel Gauge pointer should pause at each of these following positions: E, 1/4, 1/2, 3/4, Full, and back to E. Q: Does the Fuel Gauge function as described above? YES: Go To 3 NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. FUEL LEVEL SENSOR WIRING Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Disconnect the PCM C2 and C3 harness connectors. Measure the resistance of the (N4) Fuel Level Sensor Signal circuit between the Fuel Pump Module harness connector and the PCM harness connector. Measure the resistance of the (K900) Sensor Ground circuit between the Fuel Pump Module harness connector and the PCM harness connector. Q: Is the resistance below 5.0 ohms on both circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 215 YES: Replace the Fuel Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the circuits with a resistance above 5.0 ohms for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Gauge Inoperative - Gas Engines ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module - Instrument cluster DIAGNOSTIC TEST 1. POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any PCM DTCs? YES: Refer to the DRIVEABILITY category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Perform the Instrument Cluster Self Test. NOTE: The Self Test can be initiated manually by depressing and holding the Trip Reset button while turning the ignition on, or by using the DRBIII(R). Observe the gauge in question while the Instrument Cluster performs the Self Test. The gauges should position at the following calibrations points: Speedometer MPH: 0, 20, 60, 90 Tachometer Gas: 0, 1000, 3000, 6000 Fuel: E, 1/4, 1/2, 3/4, F Coolant: Cold, 1/4, 1/2, 3/4, HI Volts: 6, 9, 12, 15, 17 Q: Did the gauge in question operate properly? YES: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wire harness. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test PRNDL Not Displaying Correct Position (EATX Vehicles) PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster DIAGNOSTIC TEST 1. DTC PRESENT NOTE: - Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle. - Ensure that there is communication between the Cluster and PCM before proceeding with this test. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 216 - Diagnose and repair any DTCs before proceeding with this test. - Ensure that the PCM passes the Shift Lever Test with the DRBIII(R) before proceeding with this test. Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any MIC or PCM DTCs? YES: Refer to the correct symptom list for problems related to DTCs. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test. Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the PRNDL display during the Self Test. Q: Did any part of the VF display fail to illuminate? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wiring harness, refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off SEAT BELT WARNING INDICATOR ALWAYS OFF Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 217 Seat Belt Warning Indicator Always Off POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster Diagnostic Art Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 218 1. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 219 Seat Belt Warning Indicator Always Off - Standard Cab POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 220 1. (G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on SEAT BELT WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 221 Seat Belt Warning Indicator Always On POSSIBLE CAUSES - (Z951) Seat belt switch ground circuit for an open - (G10) Seat belt switch sense circuit open - Seat belt switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 222 DIAGNOSTIC TEST 1. CHECK THE OPERATION OF THE SEAT BELT SWITCH Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate for approximately 4 seconds and then turn off? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Measure the resistance between ground and the (Z951) Seat Belt Switch Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 223 3. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 224 Seat Belt Warning Indicator Always On - Standard Cab POSSIBLE CAUSES - (F983) Fused ignition switch output (run-acc) circuit open - (Z951) Seat belt switch ground circuit open - (G10) Seat belt switch sense circuit open - Seat belt tensioner reducer Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 225 - Seat belt switch - Instrument cluster 1. (F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN Turn the ignition off. Disconnect the Seat Belt Tensioner Reducer harness connector. Turn the ignition on. Measure the voltage between the (F983) Fused Ignition Switch Output (Run-Acc) circuit and ground in the Tensioner Reducer harness connector. Q: Is the voltage above 10.5 volts? YES: Go To 2 NO: Repair the (F983) Fused Ignition Switch Output (Run-Acc) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. SEAT BELT TENSIONER REDUCER Ensure that the Seat Belt Tensioner Reducer harness connector is connected. Measure the voltage between the (G10) Seat Belt Switch Sense circuit and ground in the Seat Belt Tensioner Reducer harness connector (cavity 2). Q: Is there any voltage present? YES: Go To 3 NO: Replace the Seat Belt Tensioner Reducer. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. SEAT BELT SWITCH Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 226 Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Measure the resistance between ground and the (Z951) Seat Belt Switch circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 227 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Open DRIVER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 228 Driver Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z75) driver door ajar switch ground circuit - Open (G75) driver door ajar switch sense circuit - Open driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 229 DIAGNOSTIC TEST 1. OPEN DRIVER DOOR AJAR SWITCH Disconnect the Driver Door Latch connector. Connect a jumper wire between the (G75) Sense circuit and the (Z75) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z75) DRIVER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z75) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES:Go To 3 NO: Repair the (Z75) Driver Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 230 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G75) Driver Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G75) Driver Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Shorted to Ground DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 231 Driver Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G75) Driver door ajar switch sense circuit short to ground - Driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 232 DIAGNOSTIC TEST 1. DRIVER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Driver Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G75) Driver Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G75) Driver Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 233 LEFT REAR DOOR AJAR CIRCUIT OPEN Left Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z79) left rear door ajar switch ground circuit - Open (G77) left rear door ajar switch sense circuit - Open left rear door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 234 - Instrument cluster DIAGNOSTIC TEST 1. OPEN LEFT REAR DOOR AJAR SWITCH Disconnect the Left Rear Door Latch connector. Connect a jumper wire between the (G77) Sense circuit and the Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO:Go To 2 2. OPEN (Z79) LEFT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z79) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z79) Left Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 235 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G77) Left Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Shorted to Ground LEFT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 236 Left Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G77) Left rear door ajar switch sense circuit short to ground - Left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 237 DIAGNOSTIC TEST 1. LEFT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Left Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G77) Left Rear Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 238 PASSENGER DOOR AJAR CIRCUIT OPEN Passenger Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z74) passenger door ajar switch ground circuit - Open (G74) passenger door ajar switch sense circuit - Open passenger door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 239 - Instrument cluster DIAGNOSTIC TEST 1. OPEN PASSENGER DOOR AJAR SWITCH Disconnect the Passenger Door Latch connector. Connect a jumper wire between the (G74) Sense circuit and the (Z74) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z74) PASSENGER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z74) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z74) Passenger Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 240 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G74) Passenger Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G74) Passenger Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Shorted to Ground PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 241 Passenger Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G74) Passenger door ajar switch sense circuit short to ground - Passenger door ajar switch - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 242 1. PASSENGER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Passenger Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G74) Passenger Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G74) Passenger Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Open RIGHT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 243 Right Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z72) right rear door ajar switch ground circuit - Open (G76) right rear door ajar switch sense circuit - Open right rear door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 244 - Instrument cluster DIAGNOSTIC TEST 1. OPEN RIGHT REAR DOOR AJAR SWITCH Disconnect the Right Rear Door Latch connector. Connect a jumper wire between the (G76) Sense circuit and the (Z72) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Right Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z72) RIGHT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z72) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z72) Right Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 245 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G76) Right Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Shorted to Ground RIGHT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 246 Right Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G76) Right rear door ajar switch sense circuit short to ground - Right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 247 DIAGNOSTIC TEST 1. RIGHT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Right Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Right Rear Door Ajar Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G76) Right Rear Door Ajar Switch Sense circuit and test for a short to ground. Q: Does the test light illuminate brightly? YES: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Average Fuel Economy Inaccurate or Wrong AVERAGE FUEL ECONOMY INACCURATE OR WRONG Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 248 POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. CMTC or EVIC Inoperative CMTC OR EVIC INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 249 CMTC Or EVIC Inoperative POSSIBLE CAUSES - (F21) Fused ignition switch output (run/start) circuit open - (Z13) Electronic overhead module ground circuit open - Electronic overhead module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 250 1. (F21) FUSED IGNITION RUN/START CIRCUIT OPEN NOTE: Diagnose and repair any MIC, FCM, PCM, or Communication DTCs before proceeding. Turn the ignition off. Disconnect the Electronic Overhead Module harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 0.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (Z13) ELECTRONIC OVERHEAD MODULE GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance between ground and the (Z13) Electronic Overhead Module Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z13) Electronic Overhead Module Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Compass Test Failure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 251 COMPASS TEST FAILURE WHEN MONITORED With the ignition on. SET CONDITION The Electronic Overhead Module (EOM) display reads "FAILED SELF TEST." POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Depress and hold the RESET and C/T buttons while turning the ignition on. NOTE: This test may also be performed using the DRBIII(R). Q: Does the EOM or DRBIII(R) display "FAILED SELF TEST"? YES: Replace the EOM. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Distance to Empty Inaccurate or Wrong DISTANCE TO EMPTY INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Elapsed Ignition On Time Inaccurate or Wrong ELAPSED IGNITION ON TIME INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 252 configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Temperature Display Inaccurate or Inoperative TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Electronic overhead module 1. AMBIENT TEMPERATURE SENSOR NOTE: - Diagnose and repair any FCM, EOM, PCM, or Communication DTCs before proceeding with this test. - The Ambient Temperature Sensor is hardwired to the FCM (Diesel), or to the PCM. Ambient temperature information is transmitted to the EOM via the PCI Bus. Turn the ignition off. Disconnect the Ambient Temperature Sensor harness connector. Measure the resistance of the Ambient Temperature Sensor using the following temperature/resistance values: 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.88 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms 50° C (122° F) Sensor Resistance = 3.33 - 3.88 Kilohms Q: Is the Ambient Temperature Sensor resistance measurement within the min/max specifications? YES: Go To 2 NO: Replace the Ambient Temperature Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 253 2. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Press and hold the C/T and Reset buttons. Turn the ignition on. NOTE: NOTE: The self test can also be performed using the DRBIII(R). Observe the EOM display at the conclusion of the self test. Q: Does the EOM display "Passed Self Test"? YES: Test Complete. NO: Replace and configure the EOM. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Trip Odometer Inaccurate or Wrong TRIP ODOMETER INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC VEHICLE INFORMATION CENTER NOTE: - Diagnose and repair any FIDEM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the OEM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. All Door Locks Inoperative ALL DOOR LOCKS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 254 All Door Locks Inoperative POSSIBLE CAUSES - DTC present - Fuse #22 open - (A941) Fuse B+ circuit open - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 255 Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock or Cluster related DTC's? YES: Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. FUSE #22 OPEN Test both sides of fuse #22 in the PDC. Q: Is there 12 volts on both sides of fuse #22? YES: Go To 3 NO: Replace the fuse if open and retry the system. If the fuse blows, locate and repair a short to the Instrument Cluster. The 12 volt supply to the fuse is a bus bar in the PDC. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. (A941) FUSED B+ CIRCUIT OPEN Turn the ignition off. Remove the instrument cluster. Measure the voltage between the (A941) Fused B+ circuit and ground (cavity 2 in the C1 connector to ground). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 256 Q: Is the voltage above 10.0 volts on the Fused B+ circuit? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Fused B+ circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Automatic (Rolling) Door Locks Inoperative AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Door ajar switch status incorrect - TPS or VSS DTC's - Auto door locks not enabled - Instrument cluster Diagnostic Test 1. CHECK THE DOOR AJAR SWITCH STATUS Ensure all doors are closed. With the DRBIII, enter "Electro/Mech Cluster" then "Input/Output" and observe all of the Door Ajar states. Q: Does the DRBIII display CLOSED for any door ajar state? YES: Select the appropriate Door Ajar Circuit Shorted: NO: Go To 2 2. ANY TPS OR VSS RELATED DTC'S With the DRBIII read "Engine" and "Anti-Lock Brakes" DTC's. Q: Does the DRBIII display any Throttle Position Sensor or Vehicle Speed Sensor related DTC's? YES: Diagnose and repair the DTC's. NO: Go To 3 3. ENABLE AUTO DOOR LOCKS With the DRBIII, enter "Electron/Mech Cluster" then "Miscellaneous" and observe the rolling door lock status. Q: Does the DRBIII display ROLLING DOOR LOCKS: ENABLED YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: With the DRBIII, enable the Auto Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 257 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Cylinder Lock Switch Inoperative CYLINDER LOCK SWITCH INOPERATIVE Cylinder Lock Switch Inoperative POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 258 DTC PRESENT - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch mux circuit open - (G163) Cylinder lock switch mux wire short to ground - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Turn the ignition on. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 259 Measure the voltage between (G163) Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 260 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Door Lock Inhibit Inoperative DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster Diagnostic Test 1. CHIME INOPERATIVE Turn the ignition off but leave the key in the ignition. Open the drivers door. Q: Does the chime sound? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Perform the test "KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE". See: Chime System/Key In Ignition and Drivers Door Open Chime Inoperative Driver Door Fails to Lock and Unlock DRIVER DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 261 Driver Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P1) Door unlock driver left front wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 262 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P1) Door Unlock Driver Left Front circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Driver Door lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 263 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Driver Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P1) DOOR UNLOCK DRIVER LEFT FRONT WIRE OPEN Measure the resistance of the (P1) Door Unlock Driver Left Front circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P1) Door Unlock Driver Left Front wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Fails to Lock & Unlock LEFT REAR DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 264 Left Rear Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P5) Door unlock driver left rear wire open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 265 - Door latch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks to diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P5) Door Unlock Driver Left Rear circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the left doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 266 Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Left Rear Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P5) DOOR UNLOCK DRIVER LEFT REAR WIRE OPEN Measure the resistance of the (P5) Door Unlock Driver Left Rear circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P5) Door Unlock Driver Left Rear wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Door Lock Motor Inoperative Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 267 ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Door lock driver or door unlock driver circuit open - Door latch Diagnostic Test 1. CHECK DOOR LOCK MOTOR CIRCUIT With the DRBIII(R), read DTCs. If there are any door lock related DTC's, refer to symptom list for problems related to Power Door Locks and diagnose and repair the DTC's. Disconnect the inoperative Door Latch connector. Connect a 12 volt test light between the Door Lock Driver and the Door Unlock Driver circuits in the latch connector. NOTE: Graphic shows Passenger Latch - all others similar. Operate the door locks several time in the lock and unlock positions from a door lock switch and observe the test light. Q: Does the test light illuminate brightly when the locks are actuated in both directions? YES: Replace the Door latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the appropriate Door Lock Driver or Door Unlock Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Doors Fail to Lock and Unlock - Quad Cab RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 268 Right Doors Fail To Lock And Unlock - Quad Cab POSSIBLE CAUSES - DTC present - (P392) Door lock driver right doors wire open - (G778) Door unlock driver right doors wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 269 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (G778) Door Unlock Driver Right Doors circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P392) Door Lock Driver Right Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Right Doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 270 NO: Go To 3 3. (P392) DOOR LOCK DRIVER RIGHT DOORS WIRE OPEN Disconnect the Passenger Door Latch connector. Measure the resistance of the (P392) Door Lock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P392) Door Lock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G778) DOOR UNLOCK DRIVER RIGHT DOORS WIRE OPEN Measure the resistance of the (G778) Door Unlock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST-VER 1. NO: Repair the (G778) Door Unlock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test RKE Inoperative RKE INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 271 POSSIBLE CAUSES - DTC present - Transmitter not programmed - RKE transmitter - Remote keyless entry module Diagnostic Test 1. DTC PRESENT With the DRBIII(R), read DTCs. Attempt to operate the door locks with the RKE transmitter. Q: Does the DRBIII(R) display RKE FOB BATTERY LOW? YES: Refer to symptom RKE FOB BATTERY LOW in this category. NO: Go To 2 2. 9001 TESTER AVAILABLE Q: Do you have access to the Miller Special Tool "9001 RF DETECTOR"? NO: Go To 3 YES: Go To 5 3. TRANSMITTER NOT PROGRAMMED Turn the ignition on. Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarmed Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Try the door locks using the Transmitter. Q: Does the RKE System operate properly? YES: Repair complete. Check with the customer to see if the other transmitters) are operating properly. They may have to be programmed also. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. SUBSTITUTE A KNOWN GOOD TRANSMITTER Secure a known good transmitter. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 272 With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Lock and Unlock the vehicle using the transmitter. Q: Does the RKE System operate properly? YES: Replace the original transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. TEST TRANSMITTER WITH TESTER Using the 9001 RF Detector, follow the instructions on the back of the tester and test the transmitter several times. Q: Does the signal strength measure "STRONG"? YES: Go To 6. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. PROGRAM RKE TRANSMITTER WITH THE DRBIII(R) Turn the ignition on Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarm Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, then PROGRAM New Fob. Follow the instructions on the screen. Exit PROGRAM RKE. Activate the Door Locks using the RKE Transmitter. NOTE: When repairs are complete, ensure all transmitters used with the vehicle have been programmed. Q: Did the door locks respond properly to the RKE transmitter commands? YES: Repair complete. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Alarm Trips On Its Own ALARM TRIPS ON ITS OWN Diagnostic Test 1. LAST VTSS CAUSE With the DRBIII(R) in Inputs/Outputs, read the Last VTSS Cause state. Q: Were there any causes displayed? YES: Check for a possible intermittent condition with the circuit indicated by the DRBIII(R). Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: The condition that caused this symptom is currently not present. Inspect the related wiring harness for a possible intermittent condition. Look for any chafed, pierced, pinched or partially broken wires. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Cylinder Lock Switch INOP CYLINDER LOCK SWITCH INOP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 273 Cylinder Lock Switch Inop POSSIBLE CAUSES - DTC present - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch MUX circuit open - (G163) Cylinder lock switch MUX wire short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 274 - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Measure the voltage between (G163) Cylinder Lock Switch MUX circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 275 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 276 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Does Not Trip VTSS DRIVER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the DRIVER DOOR AJAR SW status. Open the driver door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom DRIVER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the driver's door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the driver door lock. Attempt to trip the VTSS by opening the drivers door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 277 Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Headlamps Fail to Flash When Alarm Is Tripped HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster 1. CHECK FCM DTCS AND HIGH BEAM HEADLAMP OPERATION Attempt to operate the exterior lamps with the headlamp switch. With the DRBIII(R), read FCM DTCs. Q: Were there any problems found? YES: Refer to symptom list for problems related to Exterior Lighting. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Horn Fails to Sound When Alarm Is Tripped HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to the Ignition, Power, Accessory category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 2 2. HORN CIRCUIT DIAGNOSTICS Q: Does the horn operate from the horn button? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Refer to symptom Horns Inoperative in the Ignition, Power, Accessory category. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Left Rear Door Does Not Trip VTSS (4 Door) LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 278 - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Left Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom LEFT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the left rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the left rear door lock. Attempt to trip the VTSS by opening the left rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Does Not Trip VTSS PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the passenger door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom PASSENGER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 279 2. ATTEMPT TO TRIP VTSS Open the passenger door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the passenger door lock. Attempt to trip the VTSS by opening the passenger door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Does Not Trip VTSS (4 Door) RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Right Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom RIGHT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the right rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the right rear door lock. Attempt to trip the VTSS by opening the right rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 280 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test VTSS Will Not Arm Properly VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster 1. ATTEMPT TO ENABLE THE VTSS Turn the ignition Off to the lock position. Disconnect the battery negative cable wait 5 seconds then reconnect battery cable. Turn the ignition to the On position for 10 seconds, then back Off to the lock position and remove key. Close all doors. Using the key, lock the vehicle with the Driver Door Cylinder Lock Switch and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Go To 2 NO: Go To 3 2. VTSS NOT ENABLED Unlock the vehicle to disarm the VTSS. Ensure all doors are closed. Using the RKE key fob, lock the vehicle and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Test Complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. USE DRB TO COMMUNICATE WITH THE SKIM With the DRBIII(R), attempt to communicate with the SKIM. Q: Does the DRBIII(R) communicate with the SKIM? YES: Go To 4 NO: Refer to communication category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 4. DTC OR VTSS INHIBITORS Ensure the doors are closed. With the DRBIII(R), read the active DTC's and the ajar switch states. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 281 Q: Does the DRBIII(R) display any closed switches or related DTC's? YES: Refer to the Symptom List and diagnose the appropriate symptom in the DOOR AJAR or related category. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 5 5. CYLINDER LOCK SWITCH CIRCUIT OPEN Turn the ignition on. With the DRBIII(R), read the Driver Cylinder Lock Switch MUX volts while turning the key in the driver door lock cylinder. Q: Did the MUX voltage change from approximately 5.0 volts to 4.0 for lock and 2.4 for unlock? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. INSTRUMENT CLUSTER CYLINDER LOCK SWITCH VOLTAGE LOW Disconnect the Cylinder Lock Switch connector. Measure the voltage between Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 7 NO: Go To 8 7. CYLINDER LOCK SWITCH GROUND OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 282 Disconnect the Cylinder Lock Switch connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Ground circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 8. CYLINDER LOCK SWITCH MUX OPEN Disconnect the Cylinder Lock Switch connector. Disconnect the Instrument Cluster C2 connector. Measure the resistance of the Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Cylinder Lock Switch Mux circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: Customer Interest Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 291 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 292 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: All Technical Service Bulletins Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 298 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 299 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 304 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 305 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 306 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 307 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 308 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 309 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 310 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 311 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 312 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 313 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 318 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 319 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 320 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 326 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 327 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 328 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 329 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 330 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 331 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 332 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 333 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 334 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 335 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 340 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 341 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 342 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 343 Engine Control Module: Locations Right Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 344 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Module-Engine Control C1 Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 347 Module-Engine Control C1 Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 348 Module-Engine Control C1 Part 3 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 349 Module-Engine Control C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 350 Module-Powertrain Control C1 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 351 Module-Powertrain Control C2 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 352 Module-Powertrain Control C3 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 353 Module-Powertrain Control C4 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 356 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 357 Engine Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 358 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 359 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 360 Engine Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 361 Engine Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 362 Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 363 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 364 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 365 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 366 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming Engine Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 369 Engine Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 370 Engine Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 371 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 372 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 378 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 379 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 380 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 381 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 385 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 392 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 393 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 394 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 395 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 396 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 397 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 398 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 400 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 401 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 402 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 403 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 405 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 406 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 407 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 411 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 412 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 413 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 419 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 420 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 421 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 422 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 5.7L V-8 engine is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches the coils secondary output terminal directly to a spark plug using a rubber boot seal. Each coil is also equipped with a second output terminal. This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank. A separate primary electrical connector is used for each coil. Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The 5.7L engine will not use a conventional distributor. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Dual-Secondary Output, Ignition Coils - 2 knock Sensors - 8 Secondary Ignition Cables - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Fig.37 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 432 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 433 Air Bag Control Module: Connector Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 434 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 435 Standard Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 436 Quad Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 437 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 438 Module-Occupant Restraint Controller C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 439 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) (1) is also sometimes referred to as the Occupant Restraint Controller (ORC). The ACM is located below the instrument panel center stack in the passenger compartment of the vehicle, where it is secured by three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just forward of the instrument panel center support bracket. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electronic sating sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ACM housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ACM housing has integral mounting flanges on three corners. The mounting flange to the left of the connector receptacle has an integral locating pin on its lower surface. Both left side flanges have round mounting holes, while the flange on the right side has a slotted mounting hole. A molded plastic electrical connector (4) with two receptacles, one containing twenty-four terminal pins and the other containing thirty-two terminal pins, exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through two dedicated take outs and connectors of the instrument panel wire harness. The impact sensor and sating sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addition, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors a resistor multiplexed input from the passenger airbag on/off switch and provides a control output for the Off indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag on/off switch is set to the Off position, the ACM turns on the passenger airbag on/off switch Off indicator and will internally disable the passenger airbag from being deployed. The ACM also turns on the on/off switch Off indicator for about seven seconds each time the ignition switch is turned to the On position as a bulb test. Following the bulb test, the ACM controls the status of the Off indicator based upon the resistance of the input from the on/off switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag on/off switch circuits, and will turn on the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ACM to be operational whenever the ignition switch is in the Start or On positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or On positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 440 Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On models equipped with optional side curtain airbags, the ACM also monitors inputs from two remote side impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ACM to provide confirmation to the ACM microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact and the status of the passenger airbag on/off switch input, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. For vehicles equipped with the passenger airbag on/off switch, the passenger front airbag and seat belt tensioner will be deployed by the ACM only if enabled by the switch (passenger airbag on/off switch indicator Off) at the time of the impact. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus, and the electronic message inputs to and outputs from the ACM requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module Air Bag Control Module: Service and Repair Module WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the two wire harness connectors (3 & 4) for the Airbag Control Module (ACM) (1) from the ACM connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ACM, depress the release tab and lift the lever arm on each connector. 5. From the left side of the floor panel transmission tunnel, reach behind the module to access and loosen the screw (2) that secures the right side of the ACM to the bracket (5) on the floor panel transmission tunnel. Loosen the screw about 7 millimeters (0.25 inch). 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pin on the bottom of the ACM mounting flange from the locating hole in the mounting bracket, then slide the ACM toward the left far enough to disengage the slotted hole in the right ACM mounting flange from under the head of the previously loosened right mounting screw. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 443 1. Position the Airbag Control Module (ACM) (1) to the left side of the floor panel transmission tunnel near the ACM bracket (5). When the ACM is correctly positioned, the arrow on the ACM label will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted hole in the right ACM mounting flange under the head of the previously loosened right mounting screw (2), then engage the locating pin on the bottom of the left ACM mounting flange into the locating hole in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 N.m (9 ft.lbs.). 4. From the left side of the floor panel transmission tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screw to 12 N.m (9 ft.lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the two wire harness connectors (3 & 4) for the ACM to the ACM connector receptacle located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 444 Air Bag Control Module: Service and Repair Cover WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover (2) away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (1). 3. Remove the ACM cover from the instrument panel. INSTALLATION 1. Position the ACM cover (2) to the instrument panel. 2. Align the snap clip retainer on each side of the ACM cover with the instrument panel receptacle (1) at each side of the center bracket on the floor panel transmission tunnel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 449 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 450 Relay - Starter Motor (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 451 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 452 Starter Relay: Testing and Inspection The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12 V battery to terminals 85 an 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch, Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 453 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover (2) from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 459 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 460 In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 461 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 467 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 468 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 469 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 470 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 471 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 472 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 473 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 474 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 475 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 476 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 477 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 478 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 479 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 480 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 481 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 482 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 484 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 486 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 489 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 494 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 495 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 496 Control Module: Diagrams Module-Final Drive Control (Off Road) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 497 Module-Transfer Case Control C1 (Electronic 4x4) Module-Transfer Case Control C2 (Electric 4x4) Module-Transfer Case Control C3 (Electric 4x4) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 498 Control Module: Description and Operation The Transfer Case Control Module (TCCM) (2) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel (1). The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 499 - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for atleast 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 500 - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 ± seconds 100 msec. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel, (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds ± 50 msec . and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 501 following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 506 Heated Glass Element Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 510 Rear Defogger Relay: Description and Operation The rear window defogger (EBL) relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The EBL relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the rear window defogger grid. The EBL relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The EBL relay is located in the IPM in the engine compartment. The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the EBL relay include: - Terminal (30) receives battery current through a fuse in the IPM only when the EBL relay coil is energized. - Terminal (85) receives a ground through the EBL relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (86) receives battery current through a fused ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the rear window defogger grid lines through the EBL relay only when the EBL relay coil is energized. - Terminal (87A) is not connected to any circuit in this application. The EBL relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 511 Rear Defogger Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the EBL relay from the IPM. INSTALLATION 1. Position the EBL relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the EBL relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 516 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay Wiper Relay: Description and Operation Wiper High/Low Relay The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay > Page 522 Wiper Relay: Description and Operation Wiper On/Off Relay The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper on/off relay. The most reliable, efficient, and accurate means to diagnose the wiper on/off relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper on/off relay operation requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 528 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 529 Starter-Adjustable Pedals (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 530 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 534 Remote Switch: Diagrams Switch-Remote Radio-Left Switch-Remote Radio-Right Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 535 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 536 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control MUX circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control MUX circuit to the Integrated Power Module (IPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 537 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Testing and Inspection > Page 542 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations > Page 546 Door Position Switch: Description and Operation Vehicles that are equipped with the optional Vehicle Theft Security System (VTSS) have a door cylinder lock switch (1) secured to the back of the key lock cylinder inside the driver side front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between ground and the cylinder lock switch mux circuit input to the ElectroMechanical Instrument Cluster (EMIC) through a pigtail wire (2) connected to the left front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contains two internal resistors. One resistor value is used for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a circuit between ground and the cylinder lock switch mux circuit through one of two internal resistors for the ElectroMechanical Instrument Cluster (EMIC) when the driver side front door key lock cylinder is in the Lock, or Unlock positions. The EMIC reads the switch status through an internal pull-up, then uses this information as an input for the Vehicle Theft Security System (VTSS) operation, as well as for control of a central locking feature for the power lock system. The door cylinder lock switch and circuit may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC or its responses to the cylinder lock switch inputs. The most reliable, efficient, and accurate means to diagnose the door cylinder lock switch, the EMIC, and both the hard wired and electronic message inputs and outputs affected by the door cylinder lock switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 550 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 551 Starter-Adjustable Pedals (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 552 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 556 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 557 Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Switch-Window/Door Lock Driver C1 Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 558 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock Power Door Lock Switch: Testing and Inspection Switch-Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 561 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 562 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock Power Door Lock Switch: Service and Repair Switch-Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock > Page 565 Power Door Lock Switch: Service and Repair Switch-Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 569 Power Mirror Switch: Service and Repair The power mirror switch is included with the window/lock switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt-Driver Switch-Seat Driver Switch-Seat-Passenger (Quad Cab) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 573 Switch-Seat Passenger (Standard Cab) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 574 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 575 Power Seat Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If not OK, replace the inoperative power seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 576 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if inoperative. The heated seat temperature sensor is part of the heated seat cushion element and must be replaced as an assembly. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 580 Seat Heater Sensor: Testing and Inspection NOTE: Any resistance values (OHMS) given in the following text are supplied using the automatic range generated by a FLUKE ■ automotive meter. If another type of measuring device is used, the values generated may not be the same as the results shown here, or may have to be converted to the range used here. 1. Position the driver seat in the full rearward position. 2. Unclip the heated seat module from the bottom of the drivers seat cushion pan. 3. Back-probe the heated seat module wire harness connector, do not disconnect. Check cavity (#7 for passenger, #8 for driver seat) for a range in voltage from approx. 1.72 - 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to the appropriate wiring information for the complete heated seat system wiring diagrams. If 5 volts is not being supplied to the sensor from the module, replace the heated seat module. 4. Test the seat wire harness between the heated seat module connector and the heated seat wire harness connector for shorted or open circuits. If OK, refer to testing for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 584 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 585 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 586 Seat Heater Switch: Diagrams Switch-Heated Seat Driver Switch-Heated Seat-Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 587 Seat Heater Switch: Description and Operation The momentary, bidirectional rocker-type heated seat switch (1) provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps (2), which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time, the heated seat module interprets the second input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indicate heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 588 Seat Heater Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, Refer to electrical/instrument cluster - diagnosis and testing. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, Refer to electrical/electronic control modules/memory heated seat/mirror module - diagnosis and testing. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required. Heated Seat Switch Continuity 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, Refer to electrical/electronic control modules/memory heated seat/mirror module - diagnosis and testing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 589 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag or instrument panel service. 3. Remove the center bezel from the instrument panel. 4. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 5. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 6. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the battery negative cable. 5. Verify vehicle and system operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Switch-Sunroof Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 593 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination push button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions or the vehicle Accessory Delay System is active. When one of the switch positions is pressed it sends battery current back to the motor/ module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 594 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 599 Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 600 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 601 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 602 Sensor-Brake Fluid Level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 606 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 607 Switch-Parking Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 608 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 609 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 610 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 611 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 615 Wheel Speed Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 616 Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 617 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 618 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 619 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Sensor-Wheel Speed-ABS-Rear Sensor-Wheel Speed-ABS-Right Front Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 620 Wheel Speed Sensor: Description and Operation SENSOR- WHEEL SPEED-ABS-FRONT DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be ^ Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Wheel Speed Sensor: Initial Inspection and Diagnostic Overview WHEEL-TONE DIAGNOSIS AND TESTING REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRBIII scan tool is used to diagnose the Antilock Brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 623 Wheel Speed Sensor: Component Tests and General Diagnostics SENSOR-WHEEL SPEED-ABS-REAR DIAGNOSIS AND TESTING REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRBIII scan tool is used to diagnose the RWAL system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front SENSOR- WHEEL SPEED-ABS-FRONT REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 626 Wheel Speed Sensor: Service and Repair Rear SENSOR-WHEEL SPEED-ABS-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud (2) and install the nut. 7. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control-Left (ETC) Switch-Speed Control-Left (Except ETC) Switch-Speed Control-Right (ETC) Switch-Speed Control-Right (Except ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 636 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 637 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 644 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 645 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 646 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 647 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 648 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 649 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 650 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 651 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 652 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 653 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 654 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 655 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 656 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 657 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 658 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 659 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 660 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 661 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 662 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 663 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 664 Switch-Oil Pressure (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Testing and Inspection Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 672 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 673 Sensor-Ambient Air Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 674 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 675 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 676 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The blower motor is controlled by a rotary-type blower motor switch (6), mounted in the A/C-heater control (1). The switch allows the selection of one of four different blower motor speeds and includes an Off position. The blower motor switch provides a ground path through the A/C-heater control. The blower motor switch directs the ground path through the appropriate blower motor resistor wires, as required to achieve the selected blower motor speed. The blower motor switch is diagnosed using a DRBIII(R) scan tool. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C-heater control must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Sensor-Evaporator Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 686 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the A/C evaporator. The probe (1) for evaporator temperature sensor is attached to the evaporator coil fins. The wire lead (2) for evaporator temperature sensor is routed through an opening at the back of the HVAC housing and the connector (3) is attached to the HVAC wire harness. The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a DRBIII(R) scan tool. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 687 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Remove the wire lead for the evaporator temperature sensor (2) from the retainer located on the HVAC housing (1) and disconnect the sensor connector from the HVAC wire harness (3). 3. Remove the lower half of the HVAC housing from the upper half of the HVAC housing to gain access to the A/C evaporator. 4. Carefully remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2). 5. Remove the wire lead of the evaporator temperature sensor (3) from the upper half of the HVAC housing (4). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 688 1. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator (2). 2. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing (4). 3. Assemble the HVAC housing. 4. Install the wire lead of the evaporator temperature sensor (2) to the retainer located on the HVAC housing (1) and connect the sensor connector to the HVAC wire harness (3). 5. Install the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer-A/C Pressure (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 692 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10 ° C (50° F) due to the pressure/temperature relationship of the refrigerant.The A/C pressure transducer input to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The A/C pressure transducer is diagnosed using a DRBIII(R) scan tool. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 693 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 705 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 708 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 711 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 718 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 722 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 723 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 726 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 727 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 728 Fuel Gauge Sender: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 729 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 736 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 737 Switch-Parking Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 738 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 739 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 740 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 741 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Diagrams Sensor-Water In Fuel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 751 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 754 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 755 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 757 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 761 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 762 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 766 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 768 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 770 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Backup Lamp Switch: Connector Views Switch-Back Up Lamp (Gas) Switch-Back Up Lamp (5.7L NV5600) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 772 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 773 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the faulty backup lamp switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 777 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 778 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 779 Switch-Stop Lamp Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 780 Brake Light Switch: Description and Operation The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, faulty, or removed from its mounting position for any reason, it must be replaced with a new unit. The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Power-train Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned On and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch is diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 781 Brake Light Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. Brake Lamp Switch Tests 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the faulty brake lamp switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 782 Brake Light Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (1) near the support bracket on the lower steering column (3). 3. Disconnect the wire harness connector (5) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket (4). 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch. INSTALLATION CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket (4) on the lower steering column (3). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (1) is firmly Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 783 seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (5) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 787 Switch-Multifunction Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 788 Combination Switch: Description and Operation MULTIFUNCTION SWITCH The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (On and Off) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, low speed or high speed; and, an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch must be replaced as a unit. The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system Off. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the PCI data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned off, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the PCI data bus. The FCM energizes or de-energizes the selected low or high beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the right turn signal circuitry, and, downward to activate the left turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 789 cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. When a turn signal is activated, the multifunction switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the PCI data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the washer mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The FCM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the Off position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the FCM over the PCI data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for wiper system control. The multi-function switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 790 Combination Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. Multi-function Switch Tests 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the faulty multi-function switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 791 Combination Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 792 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. INSTALLATION 1. Slide the multi-function switch (1) into the multifunction switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 793 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.). 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clock-spring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 800 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 804 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 805 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 806 Switch-Headlamp Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 807 Headlamp Switch: Description and Operation The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (3) for exterior lighting control and a thumbwheel (2) for panel lamps dimming and interior lighting control. An optional switch has the same thumbwheel, but has an additional "Pull" function added to the rotary knob for selecting the optional front fog lamps. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and has a raised center lever to ease operator control. The thumbwheel is also plastic and knurled. The optional front fog lamp rotary knob is plastic with a smooth finish and an International Control and Display Symbol icon for "Front Fog Light" applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. The headlamp switch uses two resistor multiplexed outputs to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, and on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. - Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is pulled out to activate or pushed in to deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The FCM responds by energizing or de-energizing the front fog lamp relay in the Power Distribution Center (PDC). - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the FCM over the PCI data bus. The FCM responds by energizing or de-energizing the park lamp relay in the PDC and the high or low beam headlamp circuits. The FCM remembers which headlamp beams were last selected using the multi-function switch, and energizes those beams by default the next time the headlamps are turned On. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome defeat, dome on, parade/funeral mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the PCI data bus, and/or the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to and PWM processing of the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 808 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the left bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the instrument panel wire harness connector from the back of the headlamp switch. Headlamp Switch Tests 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the faulty headlamp switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 809 Headlamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch (4) and the left bezel (1) from the instrument panel (2) as a unit. 3. Disconnect the instrument panel wire harness connector (3) from the back of the headlamp switch. 4. Remove the three screws (3) that secure the headlamp switch (2) to the back of the instrument panel bezel (1). 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 810 1. Position the headlamp switch (2) to the back of the left instrument panel bezel (1). 2. Install and tighten the three screws (3) that secure the headlamp switch to the instrument panel bezel. Tighten the screws to 2 N.m (20 in.lbs.). 3. Position the left bezel (1) close enough to the instrument panel (2) to reconnect the instrument panel wire harness connector (3) to the back of the headlamp switch (4). 4. Reinstall the left bezel and the headlamp switch onto the instrument panel as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Switch-Horn Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 814 Horn Switch: Description and Operation The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 815 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 822 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 823 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 824 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 825 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 829 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 830 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 831 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 832 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 833 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 837 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 838 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 839 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 840 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 845 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 846 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 847 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 848 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 849 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 854 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 855 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 856 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 860 Sensor-Intake Air Temperature (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 861 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 862 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 863 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counter-clockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 867 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 868 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 869 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 870 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 874 Sensor-Map (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 875 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 876 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 877 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counter-clockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 878 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 887 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 888 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 889 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 890 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 896 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 897 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 898 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 899 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 902 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 903 Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 904 Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 905 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (3.7L/5.7L) Sensor-Oxygen-Left Rear (3.7L/5.7L LD) Sensor-Oxygen-Left Rear (5.7L HD) Sensor-Oxygen-Right Front (3.7L/5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 906 Sensor-Oxygen-Right Rear (3.7L/5.7L LD) Sensor-Oxygen-Right Rear (5.7L HD) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 907 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 908 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 909 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 913 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 914 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 915 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 919 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 928 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 929 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 930 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 931 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 935 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 940 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 941 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 942 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 943 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 948 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 949 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 950 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 951 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 952 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 957 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 961 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 962 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 963 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 964 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 969 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 970 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 971 Right Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 972 Switch-Passenger Airbag On/Off Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 973 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator (3) visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate (2) and nomenclature, and the key cylinder actuator (4). The "Off" position of the switch is illuminated when this switch position is selected, while the "On" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger airbag is enabled. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ACM, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 974 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and face plate unit (3) to the back of the bezel. 4. Remove the passenger airbag on/off switch and face plate from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and face plate unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch face plate to the back of the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Standard Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 978 Standard Cab Right Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 979 Quad Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 980 Quad Cab Right Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 981 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Sensor-Side Impact-Right 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 982 Impact Sensor: Description and Operation Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain air-bags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Air-bag Control Module (ACM). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module (ACM). The ACM microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ACM. The impact sensors and the ACM communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ACM, and the electronic message communication between the sensors and the ACM requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab Impact Sensor: Service and Repair Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 985 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 986 Impact Sensor: Service and Repair Quad Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 987 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track (4). The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire (3) and connector on the seat belt buckle-half (1), which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion (2) in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Page 991 Seat Belt Buckle Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty front seat belt buckle-half assembly. 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G301) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 996 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 997 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 998 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 999 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1000 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1004 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1005 Switch-Clutch Interlock (M/T) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1006 Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1011 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1017 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1018 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1019 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1025 Sensor-Line Pressure (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1026 Fluid Pressure Sensor/Switch: Description and Operation SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1027 Fluid Pressure Sensor/Switch: Service and Repair SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1031 Switch-Tow/Haul Overdrive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1032 Overdrive Switch: Description and Operation SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1033 Overdrive Switch: Service and Repair SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1034 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1041 Transmission Speed Sensor: Diagrams Sensor-Input Speed (RFE) Sensor-Output Speed (RFE) Sensor-Output Speed (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed Transmission Speed Sensor: Description and Operation Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: . Torque converter clutch slippage . Torque converter element speed ratio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed > Page 1044 Transmission Speed Sensor: Description and Operation Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed Transmission Speed Sensor: Service and Repair Sensor-Input Speed Sensor-Input Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed > Page 1047 Transmission Speed Sensor: Service and Repair Sensor-Output Speed Sensor-Output Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Sensor-Transmission Range (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 1051 Transmission Temperature Sensor/Switch: Description and Operation SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations > Page 1056 Switch-Axle Lock (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1061 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1062 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1063 Switch-Transfer Case Selector (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Four Wheel Drive Selector Switch: Description and Operation NV243 SWITCH-SELECTOR DESCRIPTION The selector switch assembly (1) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: ^ the 2WD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 1066 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 1067 Four Wheel Drive Selector Switch: Description and Operation NV244 GenII SWITCH-TRANSFER CASE SELECTOR DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: ^ the AWD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Gear Sensor/Switch: Locations Left Transmission (RFE) Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 1071 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 1072 Gear Sensor/Switch: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Sensor-Transfer Case Position (MTC Except Power Wagon) Sensor-Transfer Case Position (MTC Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 Gear Sensor/Switch: Description and Operation NV243 Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 1075 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 1076 Gear Sensor/Switch: Description and Operation NV244 GenII Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 1077 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 Gear Sensor/Switch: Service and Repair NV243 ASSEMBLY-SHIFT MOTOR/MODE SENSOR REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 > Page 1080 Gear Sensor/Switch: Service and Repair NV244 GenII REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Defogger Switch > Component Information > Description and Operation Rear Defogger Switch: Description and Operation The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is activated, the timing circuit integral to the A/C-heater control operates the rear window defogger (EBL) relay and the heated mirror relay. When the relays are activated, current is directed to the rear window defogger and the outside rear view mirror grids. The grids heat the rear window and rear view mirror glass to help clear the surfaces of fog or frost. An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, it energizes the timing circuit integral to the A/C-heater control, which then activates the rear window defogger (EBL) relay and the heated mirror relay. The EBL relay controls the current flow to the grids of the rear window defogger. The EBL system will be on for approximately ten minutes or until the rear window defogger switch or the ignition switch is turned off. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1088 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1089 Left Rear Door (Right Side Similar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1090 Power Window Switch: Diagrams Switch-Power Window-Left Rear Switch-Power Window-Passenger Switch-Power Window-Right Rear Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1091 Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1092 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to testing. If not OK, replace the faulty switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Passenger Power Window Switch: Service and Repair Front Passenger REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Passenger > Page 1095 Power Window Switch: Service and Repair Rear Passenger REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1100 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1101 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1102 Sensor-Washer Fluid Level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1103 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the side of the washer reservoir (4) in the engine compartment. Only the molded plastic switch mounting flange (1) and the integral connector receptacle (8) are visible when the switch is installed in the reservoir. A short nipple formation (2) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal (5) installed in the mounting hole of the reservoir. A small, molded plastic float (3) has two pivot pins (6) near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the nipple formation. A small magnet (7) is secured within the end of the float nearest the nipple, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1104 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch (3) from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch (3) through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1105 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment > Page 1111 Alignment: Specifications Ride Height HEIGHT MEASUREMENT - 4WD (LD) Measure and record the height from the ground at the centerline of the rear lower control arm bolt front tip (2) Measure and record the height from the ground at the front spindle centerline (Static Load Radius) (1). Subtract the first measurement from the second measurement. The difference between the two measurement should be 58 mm (2.3 inches) ± 3 mm (0.12 inches). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1112 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION ^ CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns ^ CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire ^ TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment ^ THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1113 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height (LD only). 7. Road test the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Independent Front Suspension Alignment: Service and Repair Independent Front Suspension Height Measurement - 4WD (LD) HEIGHT MEASUREMENT - 4WD (LD) The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. 1. Inspect tires and set to correct pressure. 2. Jounce the front of the vehicle. 6. If value is greater than 61 mm (2.4 inches), tighten the torsion bar bolt until the specification is achieved. 7. If value is less than 55 mm (2.1 inches), loosen the torsion bar bolt until the specification is achieved. 8. Repeat the previous steps until the ride height is within specifications. Height Adjustment - 4WD (LD) HEIGHT ADJUSTMENT - 4WD (LD) The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure. Also when front suspension components have been replaced. This measurement must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehicle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height. NOTE: If a height adjustment has been made, perform height measurement again on both sides of the vehicle. Alignment CAMBER AND CASTER ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. Camber and caster angle adjustments involve changing the position of the upper control arm (4) in conjunction with the slotted holes in the frame brackets, Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. TOE ADJUSTMENT 4X4 SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 1116 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. CAMBER, CASTER AND TOE ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. Camber and caster angle adjustments involve changing the position of the upper control arm (4) with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. CASTER Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 1117 Moving the front or rear position of the upper control arm (4) in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. To increase positive caster angle, move the rear position (2) of the upper control arm inward (toward the engine). Move the front (1) of the upper control arm outward (away from the engine) slightly until the original camber angle is obtained using special tool 8876 to move the upper control arm for proper adjustment. CAMBER Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm (4) for proper adjustment. After adjustment is made tighten the upper control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 1118 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 1119 Alignment: Service and Repair Link/Coil ALIGNMENT LINK/COIL SUSPENSION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. CAMBER: The wheel camber angle is preset and is not adjustable. CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Caster can be adjusted by rotating the cams (3) on the lower suspension arm. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. NOTE: Toe setting will change during tightening, Make sure to verify reading after tightening. 5. Verify the right toe setting and a straight steering wheel. 6. Road test the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Page 1120 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1125 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1126 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1130 Idle Speed: Description and Operation A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1135 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips(5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1136 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1145 5.7L The 5.7L engine (345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1146 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. 1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER) 3 CORRESPONDING SPARK PLUG NUMBER Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1154 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1155 Ignition Cable: Service and Repair REMOVAL Spark plug cables on the 5.7L engine are paired on cylinders 1/6, 2/3, 4/7 and 5/8. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. The cable retention clips must also be securely locked. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. If cable tray removal is necessary, release the 4 tray-to-manifold retention clips. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1160 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... .................................................... 0.045 in (1.14 mm) Torque Spark Plug Torque ............................................................................................................................... .................................... 13 +/- 2 ft.lbs. (18 +/- 3 Nm) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1161 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1162 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1163 Spark Plug: Testing and Inspection The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1164 Spark Plug: Service and Repair REMOVAL Eight of the 16 spark plugs are located under an ignition coil; the other 8 are not. If spark plug being removed is under coil, coil must be removed to gain access to spark plug. Refer to Ignition Coil Removal/Installation and observe all CAUTIONS and WARNINGS. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil (if coil removal is necessary), spray compressed air around coil base at cylinder head cover. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 5. Inspect spark plug condition. INSTALLATION 1. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into cylinder head by hand to avoid cross threading aluminum threads. To aid in installation, attach a piece of rubber hose, or an old spark plug boot to spark plug. 3. The 5.7L V-8 is equipped with torque critical design spark plugs. Do not exceed 15 ft.lbs. torque. Tighten spark plugs. Refer to torque specifications. 4. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 5. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. 6. Install ignition coil(s) to necessary spark plugs. 7. Install spark plug cables to remaining spark plugs. Remember to apply dielectric grease to inside of boots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All gauge pressure indications should be equal, with no more than 25% leakage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1168 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 7. Refer to - ENGINE SPECIFICATIONS) for the correct engine compression pressures. See: Engine, Cooling and Exhaust/Engine/Specifications/Mechanical Specifications/Service Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications TORQUE-SPECIFICATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1172 Drive Belt: Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1173 Drive Belt: Testing and Inspection BELT - DRIVE DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS NOTE: 5.9L Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1174 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1175 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1176 Drive Belt: Service and Repair BELT - DRIVE REMOVAL 5.7L ENGINE 1. Remove the air intake tube between intake manifold and air filter assembly.. 2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys. 3. Remove belt. 4. Gently release tensioner. INSTALLATION NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Position the drive belt over all pulleys except for the water pump pulley. 2. Rotate tensioner counterclockwise and slip the belt over the water pump pulley. 3. Gently release tensioner. 4. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1182 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips(5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1183 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: Customer Interest A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1195 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1196 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1197 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1202 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: All Technical Service Bulletins A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1208 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1209 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1210 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1215 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1216 Fluid Filter - A/T: Service and Repair FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICATION & MAINTENANCE. REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 1224 Fuel Pump Pickup Filter: Service and Repair REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs (2) at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair FILTER - ENGINE OIL REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. Daimler/Chrysler Corporation recommends a Mopar(R) or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter (3). 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket (2) with engine oil. 2. Thread filter (3) onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions WARNING: - THE A/C SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - VOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE A/C REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION AND DEATH. - THE EVAPORATION RATE OF R-134A REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134A SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. CAUTION: - Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on a R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. - Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. - Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line Hose/Line HVAC: Description and Operation Coupler-Refrigerant Line Spring-lock type refrigerant line couplers (1 and 4) are used to connect the A/C suction line (6) to the A/C accumulator (5) and, the A/C accumulator and the A/C liquid line to the A/C evaporator tubes (3). Secondary retaining clips (2 and 7) are installed over the connected couplers for added protection. The spring-lock refrigerant line couplers require special disconnect tools for disengaging the two coupler halves. The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected. Two O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. A secondary retaining clip (3) is installed over the connected coupler (5) for added protection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1234 Hose/Line HVAC: Description and Operation Plumbing The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80 millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s). High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1235 Hose/Line HVAC: Description and Operation Line-A/C Discharge The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line for the 5.9L Diesel engine is serviced as an assembly with the suction line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use correct O-ring seal will cause the refrigerant system connection to leak. The A/C discharge line has no serviceable parts except the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is removed and installed. If the A/C discharge line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1236 Hose/Line HVAC: Description and Operation Line-A/C Liquid The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The liquid line for this model consist of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The liquid lines are made from light-weight aluminum, and use braze-less fittings. The front half of the liquid line includes the high-side service port and the rear half of the liquid line contains the fixed orifice tube. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is removed and installed. If the liquid line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1237 Hose/Line HVAC: Description and Operation Line-A/C Suction The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line for the 5.9L Diesel engine is serviced as an assembly with the discharge line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The A/C suction line has no serviceable parts except for the rubber O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed and installed. If the A/C suction line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1238 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: - R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR AND R-134A CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134A SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. This is accomplished by performing a system Charge Level-Check or Fill. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the symptoms. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to Step 2. 2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the refrigerant system. 3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. 4. Proceed to Step 2 of System Low procedure. SYSTEM LOW 1. Determine if there is any R-134a refrigerant in the system. 2. Position the vehicle in a wind free work area. This will aid in detecting small leaks. 3. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the A/C system set to the following: Transmission in Park or Neutral with parking brake set - Engine idling - Mode control set to the outside air position - Blower control set to the high speed position - A/C set to the ON position - All windows open CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in a R-134a refrigerant system. 4. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line Hose/Line HVAC: Service and Repair Coupler-Refrigerant Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1). 4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting. 6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4). INSTALLATION 1. Clean any dirt or foreign material from the spring-lock type refrigerant line coupler. 2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1241 b. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak. 3. Install new O-rings (8) on the male half of the refrigerant line coupler. 4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Position the female half of the coupler over the male half of the coupler. 6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler. 7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler. 8. Install the secondary retaining clip (3) over connected coupler cage (5). 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1242 Hose/Line HVAC: Service and Repair Line-A/C Discharge REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the wire harness connector from the A/C pressure transducer (8). 4. Remove the nut (2) that secures the A/C discharge line (1) to the A/C condenser (3). 5. Disconnect the A/C discharge line from the A/C condenser and remove and discard the seal. 6. Install plugs in, or tape over the discharge line fitting and condenser inlet port. 7. Remove the nut (7) that secures the A/C discharge line to the A/C compressor (6). 8. Disconnect the A/C discharge line from the A/C compressor and remove and discard the seal. 9. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 10. Remove the A/C discharge line from the engine compartment. 11. If necessary, remove the A/C pressure transducer from the A/C discharge line. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1243 1. If removed, install the A/C pressure transducer (8) onto the A/C discharge line (1). 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the opened discharge line fitting and the inlet port on the A/C condenser (3). 4. Lubricate a new seal with clean refrigerant oil and install it onto the discharge line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Install the A/C discharge line onto the A/C condenser. 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 20 N.m (15 ft.lbs.). 7. Remove the tape or plugs from the opened fitting on the A/C discharge line and the outlet port on the A/C compressor (6). 8. Lubricate a new seal with clean refrigerant oil and install it onto the discharge line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C discharge line onto the A/C compressor. 10. Install the nut (7) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft.lbs.). 11. Connect the wire harness connector to the A/C pressure transducer. 12. Reconnect the negative battery cable. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1244 Hose/Line HVAC: Service and Repair Line-A/C Liquid Front Section REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing. 5. Remove the plastic cover from the condenser outlet stud. 6. Remove the nut (8) that secures the front section of the A/C liquid line (10) to the A/C condenser (7). 7. Disconnect the A/C liquid line from the A/C condenser and remove and discard the seal. 8. Disengage the A/C liquid line from the body retaining clips (1 and 9). 9. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line (4). 10. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the seal. 11. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser outlet port. 12. Remove the front section of the A/C liquid line from the engine compartment. INSTALLATION NOTE: The A/C liquid line is serviced in two sections. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1245 1. Position the front section of the A/C liquid line (10) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser outlet port. 3. Lubricate a new seal with clean refrigerant oil and install it onto the front liquid line spring-lock coupler fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (4). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. 6. Engage the A/C liquid line into the body retaining clips (1 and 9). 7. Lubricate a new seal with clean refrigerant oil and install it on the front liquid line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line to the outlet port of the A/C condenser (7). 9. Install the nut (8) that secures the A/C liquid line to the A/C condenser. Tighten the nut to 20 N.m (15 ft.lbs.). 10. Install the plastic cover onto the condenser outlet stud. 11. If equipped with a gasoline engine, install the air filter housing. 12. If equipped with the diesel engine, install the passenger side battery tray. 13. Reconnect the negative battery cable(s). 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Rear Section REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1246 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing. 5. Disengage the rear section of the A/C liquid line (4) from the body retaining clip (3). 6. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (10) to the rear section of the liquid line. 7. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the seal. 8. Remove the secondary retaining clip (5) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator inlet tube (6). 9. Using the proper A/C line disconnect tool, disconnect the A/C liquid line from the evaporator inlet tube and remove and discard the seal. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator inlet port. 11. Remove the rear section of the A/C liquid line from the engine compartment. INSTALLATION NOTE: The A/C liquid line is serviced in two sections. 1. Position the rear section of the A/C liquid line (4) into the engine compartment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1247 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator inlet tube (6). 3. Lubricate a new seal with clean refrigerant oil and install it on the rear liquid line spring-lock coupler fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the rear section of the A/C liquid line to the evaporator inlet tube. 5. Install the secondary retaining clip (5) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator inlet tube. 6. Engage the A/C liquid line into the body retaining clip (3). 7. Lubricate a new seal with clean refrigerant oil and install it on the front liquid line spring-lock coupler fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the rear section of the A/C liquid line to the front section of the liquid line (10). 9. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 10. If equipped with a gasoline engine, install the air filter housing. 11. If equipped with the diesel engine, install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1248 Hose/Line HVAC: Service and Repair Line-A/C Suction REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air filter housing cover. 4. Remove the nut (4) that secures the A/C suction line (5) to the A/C compressor (6). 5. Disconnect the A/C suction line from the A/C compressor and remove and discard the seal. 6. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 7. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the accumulator (5). 8. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator. 9. Remove the O-ring seals from the accumulator tube fitting and discard the seals. 10. Install plugs in, or tape over the opened suction line fitting and the accumulator outlet tube. 11. Remove the A/C suction line from the engine compartment. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1249 1. Position the A/C suction line (5) into the engine compartment. 2. Remove the tape or plugs from the opened fitting on the A/C suction line and the inlet port on the A/C compressor (6). 3. Lubricate a new seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the A/C suction line onto the A/C compressor. 5. Install the nut (4) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft.lbs.). 6. Remove the tape or plugs from the opened suction line fitting and the accumulator outlet tube. 7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the A/C suction line (6) to the spring-lock coupler (1) on the accumulator (5) and install the secondary retaining clip (7). 9. Install the air filter housing cover. 10. Reconnect the negative battery cable. 11. Evacuate the refrigerant system. 12. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S Power Steering Line/Hose: Service and Repair Hoses - I.F.S Return Hose - Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 71 Nm (52 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S > Page 1254 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir to Cooler RETURN HOSE - RESERVOIR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S > Page 1255 Power Steering Line/Hose: Service and Repair Hoses - Link/Coil Return Hose - Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (2) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 Nm (38 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S > Page 1256 4. Disconnect the pressure hose (2) at the gear (4). 5. Remove the pressure hose from the vehicle. INSTALLATION NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir to Cooler RETURN HOSE - RESERVOIR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1262 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1263 Brake Fluid: Specifications Brake Fluid ............................................................................................................................................... Mopar DOT 3 and SAE J1703 should be used If DOT 3 brake fluid is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1264 Brake Fluid: Testing and Inspection FLUID DIAGNOSIS AND TESTING BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1265 Brake Fluid: Service and Repair STANDARD PROCEDURE BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1270 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1275 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ....................................................... 16.2 qts. (15.4 L) Includes 1.0 qts. (0.9 L) for coolant reservoir. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1278 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant COOLANT DESCRIPTION ENGINE COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5°C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol-ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant > Page 1281 Coolant: Description and Operation Hoat Coolant HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/ fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/10O,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to --67.7°C (--90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1282 Coolant: Testing and Inspection DIAGNOSIS AND TESTING COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1287 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1292 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1297 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1302 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1307 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1308 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1309 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1310 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1311 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1312 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1313 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications SERVICE FILL Model 48RE ................................................................................................................ ............................................................................... 3.8Liters (4.0 Qt) Model 45RFE/545RFE 4X2 ................................................................................................................. .......................................................................................... 5.2Liters (11.0 Pt) 4X4 .............................. .............................................................................................................................................................. ............... 6.2Liters (13.0 Pt) OVERHAUL * Model 48RE .................................................................................................................. ............................................................................ 14-16L (29-33 Pt) Model 45RFE/545RFE ........................................................................................................................ ..................................................... 14-16L (29-33 Pt) *Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1316 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type .............................................................................................................. Mopar ATF+4 Automatic Transmission Fluid Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1317 Fluid - A/T: Testing and Inspection FLUID DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. FLUID CONTAMINATION Transmission fluid contamination is generally a result of: ^ adding incorrect fluid ^ failure to clean dipstick and fill tube when checking level ^ engine coolant entering the fluid . internal failure that generates debris ^ overheat that generates sludge (fluid breakdown) ^ failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1320 10. Check transmission for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1321 Fluid - A/T: Service and Repair Fluid and Filter Service FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICATION & MAINTENANCE. REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1322 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1327 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1332 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications DIESEL ENGINE - G56 ....................................................................................................................... ........................................................ 12 pts. (5.67 L) 5.7L ENGINE - G56 ............................................................................................................................. .......................................................... 10 pts. (4.7 L) GETRAG 238 ...................................................................................................................................... ........................................................... 4.2 pts. (2.2 L) NV5600 ................................................................................................................................................ ........................................................ 9.5 pts. (4.50 L) NV4500 ................................................................................................................................................ ........................................................ 8.0 pts. (3.79 L) TREMEC T-56 ..................................................................................................................................... ......................................................... 4.8 pts. (2.27 L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1335 Fluid - M/T: Fluid Type Specifications NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. NV5600 ................................................................................................................................................ ................... Mopar Manual Transmission Lubricant NV4500 ...................................................................................................................................... Mopar Synthetic 75W-85 Manual Transmission Lubricant Getrag 238 ........................................................................................................................................... ..................... Mopar ATF+4 Transmission Lubricant G 56 ..................................................................................................................................................... ..................... Mopar ATF+4 Transmission Lubricant Tremec T56 ................................................................................................................................ Mopar Synthetic 75W-85 Manual Transmission Lubricant Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1340 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1341 Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1342 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front FRONT AXLE C205F .......................................................................................................................... ............................................................................ 56 oz. (1.6 Liters) * 9 1/4 AA .................................. .............................................................................................................................................................. .. 76 oz. (2.2 Liters) * 9 1/4 AA EL ....................................................................................................... ..................................................................................... 76 oz. (2.2 Liters) * *± 1 oz (0.03 L) Rear REAR AXLE 9 1/4 ............................................................................................................................... ........................................................................ 72 oz. (2.1 L)*** (a) 10 1/2 AA .................................... .......................................................................................................................................................... 85 oz. (2.5 Liters) (a) 10 1/2 AA EL ..................................................................................................... ................................................................................... 85 oz. (2.5 Liters) (a) 11 1/2 AA ...................... .............................................................................................................................................................. ........ 122 oz. (3.6 Liters) (a) 248RBI (DANA 60) ................................................................................. ............................................................................................ 46 oz. (2.8 L)**** (a) (a)± 1 oz (0.03 L) *** With Trac-Lok add 4 oz. (118 ml) of Limited Slip Additive. **** Add 5 oz. (147 ml) of Limited Slip Additive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1345 Fluid - Differential: Fluid Type Specifications Front Axle NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. FRONT AXLE C205F .......................................................................................................................... ......................................................... Mopar Gear Lubricant 75W-90 9 1/4 AA ................................... ............................................................................................................................ Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA EL ......................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 NOTE: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Rear Axle NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. REAR AXLE 9 1/4 ............................................................................................................................... ..................................... Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL ....................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 248 RBI .............................................................................. ....................................................................................... Mopar Gear & Axle Lubricant SAE 90 NOTE: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1346 Fluid - Differential: Service and Repair 1. Raise and support the vehicle. 2. Remove the lubricant fill hole plug from the differential housing cover. 3. Remove the differential housing cover and drain the lubricant from the housing. 4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning. 5. Remove the sealant from the housing and cover surfaces. Use solvent to clean the mating surfaces. Fig. 3 6. Apply a bead of Mopar Silicone Rubber Sealant, or equivalent, to the housing cover (Fig. 6). Install the housing cover within 5 minutes after applying the sealant. 7. Install the cover and any identification tag. Tighten the cover bolts in a crisscross pattern to 41 Nm (30 ft. lbs.) torque. 8. Refill the differential with Mopar Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. Refer to Specifications for the quantity necessary. 9. Install the fill hole plug and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1351 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV241 GEN II ...................................................................................................................................... ................................................. 1.6 Liters (3.4 pts.) NV243 .................................................................................................................................................. .................................................. 1.6 Liters (3.4 pts.) NV241 GEN II ...................................................................................................................................... ................................................. 1.6 Liters (3.4 pts.) NV271 .................................................................................................................................................. ................................................ 1.89 Liters (4.0 pts.) NV273 .................................................................................................................................................. ................................................ 1.89 Liters (4.0 pts.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1354 Fluid - Transfer Case: Fluid Type Specifications Fluid Type ................................................................................................................................................... Mopar ATF +4 Automatic Transmission Fluid Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GenII Fluid - Transfer Case: Service and Repair NV241 GenII FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20 - 34 Nm (15 - 25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20 34 Nm (15 - 25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GenII > Page 1357 Fluid - Transfer Case: Service and Repair NV243 FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20 34 Nm (15 - 25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GenII > Page 1358 Fluid - Transfer Case: Service and Repair NV244 GenII FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20 - 34 Nm (15 - 25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20 - 34 Nm (15 - 25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1363 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1364 Engine Oil: Technical Service Bulletins Engine - Oil Quality/Viscosity Requirements NUMBER: 09-013-04 GROUP: Engine DATE: August 6, 2004 SUBJECT: Gasoline Engine Oil Quality And Viscosity Grades MODELS: 2005 (ND) Dakota 2005 (CS) Pacifica 2005 (DR) Ram Truck 2005 (HB) Durango 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2005 (PL) Neon 2005 (PT) PT Cruiser 2005 (RS) Town & Country/ Caravan/Voyager 2005 (TJ) Wrangler 2005 (WK) Grand Cherokee NOTE: This information applies to U.S. and Canada markets only. NOTE: For additional information and vehicles not covered by this Service Bulletin refer to the service information or the Owner Manual. DISCUSSION: This bulletin involves the engine oil to be used to service Chrysler Group gasoline engines. This symbol, found on the front of the container, means that the oil quality has been certified by the American Petroleum Institute (API) (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1365 Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. MS-6395 contains requirements, not addressed by API Certification, that provide additional protection for Chrysler Group engines. All Chrysler Group gasoline engines, irrespective of model year, should be serviced with API Certified engine oils meeting MS-6395. Chrysler Group Engines are developed, certified and filled with engine oil of the designated viscosity grade, meeting MS-6395, and should be serviced with the correct viscosity grade engine oil. The following table contains the correct viscosity grades for the 2005 model year. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ..................................................... 6.6Liters (7.0 Qt) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1368 Engine Oil: Fluid Type Specifications This information has been updatad by TSB 09-013-04 API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified. MOPAR provides engine oils, that meet or exceed this requirement. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. For 3.7L/4.7L engines SAE 5W-30 engine oil is recommended for all operating temperatures. For 5.7L engines SAE 5W-20 engine oil is recommended for all operating temperatures.These engine oils improve low temperature starting and vehicle fuel economy. Refer to your engine oil filler cap for the recommended engine oil viscosity for your vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Engine Oil: Initial Inspection and Diagnostic Overview DIAGNOSIS AND TESTING - ENGINE OIL LEAK Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed: 1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak. 2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. 3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair defect. 4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not positively identified at this time, proceed with the air leak detection test method. Air Leak Detection Test Method 1. Remove the PCV valve from the IAFM. Cap or plug the PCV valve grommet. 2. Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure. 3. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair defect. 4. If the leakage occurs at the rear oil seal area, refer to Inspection for Rear Seal Area Leak. 5. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve. 6. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1371 Engine Oil: Component Tests and General Diagnostics INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. 4. If no leaks are detected, pressurize the crankcase as outlined in the, Inspection (Engine oil Leaks in general). CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Page 1372 Engine Oil: Service and Repair OIL STANDARD PROCEDURE - ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm (25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1377 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1378 Power Steering Fluid: Technical Service Bulletins Power Steering - Additive Prohibition NUMBER: 19-010-04 GROUP: Steering DATE: November 29, 2004 SUBJECT: Power Steering Fluid Contamination MODELS: 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2004 - 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1379 Power Steering Fluid: Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1380 Power Steering Fluid: Description and Operation FLUID NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1381 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4 Do not overfill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CAPACITY Refer to the A/C Underhood Specification Label located in the engine compartment. 2004 Ram Gas ...................................................................................................................................................... .................................. 0.728kg (1.604 lbs.) 2004 Ram Diesel ............................................................. ....................................................................................................................... 0.850kg (1.873 lbs.) 2005 Ram Gas .................................................................................................................................... .................................................... 0.728kg (1.604 lbs.) 2005 Ram Diesel ........................................... ......................................................................................................................................... 0.850kg (1.873 lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1386 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1387 Refrigerant: Description and Operation The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1388 Refrigerant: Service and Repair WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Always refer to the underhood HVAC Specification Label for the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the underhood HVAC Specification Label. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH PRESSURE) VALVE AT THIS TIME. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Fill .................................................................................................................................. ............................................................ 6 oz (180 ml) Accumulator ......................................................................................................................................... ............................................................... 2 oz (60 ml) Condenser ........................................................................................................................................... ................................................................. 1 oz (30 ml) Evaporator ........................................................................................................................................... ................................................................ 2 oz (60 ml) Compressor ..................................................................................................................................... Drain and measure the oil from the old compressor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1393 Refrigerant Oil: Fluid Type Specifications Denso 10S17 Compressor .................................................................................................................. ........................................................... ND-8 PAG Oil Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1394 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the underhood A/C system specification tag). The Sanden SD-7 A/C compressor used in this vehicle is designed to use ND-15 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for the 5.9L Diesel engine. The Denso 10S17 A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for the 3.7L, 4.7L, 5.7L and 8.3L engines. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1395 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the underhood A/C System Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when an accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. When an A/C compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding Brake Bleeding: Service and Repair Hydraulic Brake Booster Bleeding HYDRAULIC BOOSTER STANDARD PROCEDURE BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 1400 Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 1401 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE MANUAL BLEEDING Use Mopar(R) brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. PRESSURE BLEEDING Use Mopar(R) brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 1402 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Positive Temperature Coefficients (PTC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1413 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1414 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1415 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1416 Fuse: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1417 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1418 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1419 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1423 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1424 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1425 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1428 Fuse Block: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1429 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1430 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1431 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1435 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1436 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1437 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1438 Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1439 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1440 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1441 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1442 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC's, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. On vehicles with a diesel engine, the ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1456 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1457 Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1458 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1459 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1460 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, The rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1461 wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1462 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1466 Wheel Bearing: Service and Repair HUB/BEARING - 4X4 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using special tool 8677. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using special tool 8677. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. 9. Remove the support and lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair WHEEL COVER REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with Dual Rear Wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. 4. The wheel skins can now be removed from the wheel. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. INSTALLATION REAR 1. Install one 1 1/2 inch valve stem extension on each rear inner wheel. NOTE: A 3/8 inch drive 10mm deep wheel socket with a 10 inch or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 inch valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike the wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS 1500 Series Lug Nut 9/16 X 18 with 60° Cone LD .............................................................................................................................. 183 Nm (135 ft. lbs.) 2500 Series Lug Nut 9/16 X 18 with 60° Cone HD SRW .................................................................................................................... 197 Nm (145 ft. lbs.) 3500 Series Lug Nut 9/16 X 18 with Flat Washer HD DRW ............................................................................................................... 210 Nm (155 ft. lbs.) 8-lug. (SRT-10). 6-bolt pattern. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1477 Wheel Fastener: Service and Repair STUDS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using special tool C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1478 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications All gauge pressure indications should be equal, with no more than 25% leakage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1484 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 7. Refer to - ENGINE SPECIFICATIONS) for the correct engine compression pressures. See: Specifications/Mechanical Specifications/Service Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications CAMSHAFT Bearing Journal Diameter No. 1 .................................................................................................................................................... .............................................. 58.2 mm (2.29 inch) No. 2 .................................................................... .............................................................................................................................. 57.8 mm (2.27 inch) No. 3 ........................................................................................................................................... ....................................................... 57.4 mm (2.26 inch) No. 4 ........................................................... ....................................................................................................................................... 57.0 mm (2.24 inch) No. 5 .................................................................................................................................. ............................................................ 43.633 mm (1.72 inch) Bearing To Journal Clearance Standard No. 1 .................................................................................................................................................... ................... 0.040 - 0.080 mm (0.0015- .003 inch) No. 2 .................................................................... .................................................................................................. 0.050 -0.090 mm (0.0019- .0035 inch) No. 3 ........................................................................................................................................... ............................ 0.040 - 0.080 mm (0.0015- .003 inch) No. 4 ........................................................... .......................................................................................................... 0.050 - 0.090 mm (0.0019.0035 inch) No. 5 ................................................................................................................................. ...................................... 0.040 - 0.080 mm (0.0015- .003 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... ................................................. 122 Nm (90 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft End Play ................................................................................................................................................ 0.080 0.290 mm (0.0031 - 0.0114 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1495 Camshaft: Service and Repair CAMSHAFT REMOVAL - CAMSHAFT CORE HOLE PLUG CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug. 1. Remove the rear cam bearing core plug. REMOVAL - CAMSHAFT 1. Remove the battery negative cable. 2. Remove the air cleaner assembly. 3. Drain coolant. 4. Remove the accessory drive belt. 5. Remove the generator. 6. Remove the A/C compressor, and set aside. 7. Remove the radiator. 8. Remove intake manifold. 9. Remove cylinder head covers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1496 10. Remove both left and right cylinder heads (4). 11. Remove the oil pan. 12. Remove timing case cover (1). 13. Remove the oil pick up tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1497 14. Remove the oil pump (figure 2). 15. Remove timing chain (2). 16. Remove camshaft tensioner/thrust plate assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1498 NOTE: Identify lifters to ensure installation in original location. 17. Remove the tappets (2) and retainer (1) assembly. 18. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes (figure 5). INSPECTION 1. The cam bearings are not serviceable. Do not attempt to replace cam bearings for any reason. INSTALLATION - CAMSHAFT CORE HOLE PLUG 1. Clean core hole in block. NOTE: Do not apply adhesive to the new core hole plug. A new plug will have adhesive pre-applied. 2. Install a new core hole plug at the rear of camshaft, using suitable flat faced tool. The plug must be fully seated on the cylinder block shoulder. INSTALLATION - CAMSHAFT CAUTION: The 5.7L LX engine uses a unique camshaft for use with the Multi Displacement System. When installing a new camshaft, the replacement camshaft must be compatible with the Multi Displacement System. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1499 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft (figure]). 2. Install camshaft Tensioner plate assembly. Tighten bolts to 28 Nm (250 inch lbs.) torque. 3. Install timing chain and sprockets. 4. Measure camshaft end play. If not within limits install a new thrust plate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1500 5. Install the oil pump (figure2). 6. Install the oil pick up tube. 7. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. CAUTION: The 5.7L LX engine uses both standard roller tappets and deactivating roller tappets, for use with the Multi Displacement System. The deactivating roller tappets must be used in cylinders 1,4,6,7. The deactivating tappets can be identified by the two holes in the side of the tappet body, for the latching pins. 8. Install tappets (2) and retaining yoke assembly (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1501 9. Install both left and right cylinder heads (4). 10. Install pushrods. 11. Install rocker arms. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1502 12. Install timing case cover (figure 4). 13. Install the oil pan. 14. Install cylinder head covers. 15. Install intake manifold. 16. Install the A/C compressor (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1503 17. Install the generator (2). 18. Install the accessory drive belt. 19. Install the radiator. 20. Install the air cleaner assembly. 21. Install the battery negative cable. 22. Refill coolant. 23. Refill engine oil. 24. Start engine and check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection TAPPETS - HYDRAULIC ROLLER DIAGNOSIS AND TESTING - HYDRAULIC TAPPETS Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207 - 552 kPa (30 - 70 psi) at 3,000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two conditions could be responsible for noisy tappets. OIL LEVEL HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. LOW Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out. TAPPET NOISE DIAGNOSIS 1. To determine source of tappet noise, crank over engine with cylinder head covers removed. 2. Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. 3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leakdown around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. 4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it's probably not the tappets. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1507 Lifter / Lash Adjuster: Service and Repair TAPPETS - HYDRAULIC ROLLER REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove the air cleaner. 3. Remove intake manifold 4. Remove cylinder head cover. 5. Remove rocker arm assembly and push rods. Identify push rods to ensure installation in original location. 6. Remove the cylinder head. 7. Remove bolt from tappet retainer (1). 8. Remove tappet retainer (1). 9. Pull tappet out of bore with a twisting motion. If all tappets are to be removed and reused, identify tappets to ensure installation in original location. 10. Check camshaft lobes for abnormal wear. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1508 1. Lubricate tappets. 2. Install tappets in their original positions. 3. Install tappet retainer (1). Install the tappet retainer bolt and tighten to 12 Nm (106 inch lbs.) torque. 4. Install cylinder head. 5. Install pushrods and rocker arm assembly. 6. Install cylinder head cover. 7. Install intake manifold. 8. Install the air cleaner. 9. Connect the negative cable to the battery. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. 10. Road test vehicle and check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair ROCKER ARM REMOVAL 1. Remove cylinder head cover. 2. Install pushrod retaining plate (1) special tool 9070. 3. Loosen the rocker shafts using the sequence provided. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an "I". 4. Remove the rocker shafts. Note location for reassembly. CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1512 5. Remove the pushrods. Note pushrod location for reassembly. CAUTION: Do not remove the retainers from the rocker shaft. The assembly tangs (1) at the bottom of the retainers (2) can be damaged, causing the assembly tangs to break off, and get into the engine. INSTALLATION CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. 1. Install the push rods in the same order as removed. 2. Install the pushrod retaining plate (1) special tool 9070. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1513 CAUTION: Ensure that retainers (2) and rocker arms (4) are not overlapped when torquing bolts. CAUTION: Verify that pushrod is installed into rocker arm (4) and tappet correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter "I". 3. Install rocker shaft assemblies in the same order as removed. 4. Tighten the rocker shaft bolts to 22 Nm (195 inch lbs.) torque, using the sequence provided. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1514 5. Remove pushrod retaining plate (1) special tool 9070. 6. Install cylinder head cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance ............................................................................................................................................. 0.020 0.060 mm (0.0007 - 0.0023 inch) Out of Round (MAX) ....................................................................... ........................................................................................... 0.005 mm (0.0002 inch) Taper (MAX) ..... .............................................................................................................................................................. ............ 0.003 mm (0.0001 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING RODS Piston Pin Bore Diameter .............................................................................................................................. 23.955 - 23.975 mm (0.9431 - 0.9438 inch) Side Clearance ......................................................................................................................................................... 0.10 - 0.35 mm (0.003 - 0.0137 inch) Connecting Rod Journal Diameter ............................................................................................................................................... 53.992 54.008 mm (2.125 - 2.126 inch) Out of Round (MAX) ......................................................................... ......................................................................................... 0.005 mm (0.0002 inch) Taper (MAX) ....... .............................................................................................................................................................. .......... 0.003 mm (0.0001 inch) Connecting Rod Bolts CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to ..................................................................................................................................................... 21 Nm (15 ft. lbs.) plus a 90° turn. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1522 Connecting Rod: Description and Operation PISTON & CONNECTING ROD DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a "fractured cap" design. A pressed fit piston pin is used to attach the piston and connecting rod. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1523 Connecting Rod: Service and Repair PISTON & CONNECTING ROD REMOVAL 1. Disconnect negative cable from battery. 2. Remove the following components: ^ Oil pan and gasket/windage tray. ^ Cylinder head covers. ^ Timing chain cover. ^ Cylinder head(s). 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing piston from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1524 4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur 6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces. 7. Carefully remove piston rings from piston(s), starting from the top ring down. CLEANING CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly. INSPECTION Check the connecting rod journal for excessive wear, taper and scoring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1525 Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. INSTALLATION 1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil. 4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads. 5. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. 6. Wipe cylinder bore clean and lubricate with engine oil. 7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1526 CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. 9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 Nm (15 ft. lbs.) plus a 90° turn. 10. Install the following components: ^ Cylinder head(s). ^ Cylinder head covers. ^ Install the intake manifold. ^ Oil pan and gasket/windage tray. 11. Fill crankcase with proper engine oil to correct level. 12. Connect negative cable to battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications CRANKSHAFT Main Bearing Journal Diameter ........................................................................................................................ 64.988 - 65.012 mm (2.5585 - 2.5595 inch) Bearing Clearance ................................................................................................................................................... 0.023 - 0.051 mm (0.0009 - 0.002 inch) Crankshaft Main Bearings Clean and oil all cap bolts. Install all cap bolts and alternately tighten in two steps using the following sequence. Step 1 - ................................................................................................................................................ .............................. 27 Nm (20 ft. lbs.) torque. Step 2 ........................................................................................................................................................... Turn main cap bolts an additional 90°. Install the crossbolts with new washer/gasket. Start with crossbolt - A Torque each crossbolt to .................................................................................................................................................... 28 Nm (21 ft. lbs.) torque. Repeat crossbolt torque procedure. Measure crankshaft end play. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1530 Crankshaft Main Bearing: Service and Repair BEARINGS - CRANKSHAFT MAIN STANDARD PROCEDURE - CRANKSHAFT MAIN BEARING - FITTING MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) Crankshaft removed from the cylinder block. Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal. The maximum allowable taper is 0.008 mm (0.0004 inch) and maximum out of round is 0.005 mm (0.0002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. CRANKSHAFT MAIN BEARING SELECTION The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5. NOTE: Service main bearings are coded. These codes identify what size (grade) the bearing is. MAIN BEARING SELECTION CHART - 5.7L INSPECTION Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated. NOTE: If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced. Inspect the back of the inserts for fractures, scrapings or irregular wear patterns. Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair Crankshaft Seal Retainer: Service and Repair RETAINER - CRANK REAR OIL - SEAL REMOVAL 1. Disconnect negative cable from battery. 2. Remove the transmission. 3. Remove the flexplate. 4. Remove the oil pan. 5. Remove the rear oil seal retainer mounting bolts. 6. Carefully remove the retainer from the engine block. INSTALLATION 1. Thoroughly clean all gasket rescue from the engine block. 2. Use extreme care and clean all gasket rescue from the retainer. 3. Position the gasket onto the retainer. 4. Position the retainer onto the engine block. 5. Install the retainer mounting bolts. Tighten the bolts to 15 Nm (132 inch lbs.) using the procedure shown. 6. Install the oil pan. 7. Install the flexplate. 8. Install the transmission. 9. Check and verify engine oil level. 10. Start engine and check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications CRANKSHAFT Main Bearing Journal Diameter .................................................................................................................... 64.988 - 65.012 mm (2.5585 - 2.5595 inch) Bearing Clearance ............................................................................................................................................... 0.023 0.051 mm (0.0009 - 0.002 inch) Out of Round (MAX) ......................................................................... ......................................................................................... 0.005 mm (0.0002 inch) Taper (MAX) ....... .............................................................................................................................................................. .......... 0.003 mm (0.0001 inch) End Play ............................................................................................ .................................................................... 0.052 - 0.282 mm (0.002 - 0.011 inch) End Play (MAX) . .............................................................................................................................................................. ............. 0.282 mm (0.011 inch) Connecting Rod Journal Diameter .................................................................................................................... 53.992 - 54.008 mm (2.125 - 2.126 inch) Bearing Clearance ............................................................................................................................................. 0.020 0.060 mm (0.0007 - 0.0023 inch) Out of Round (MAX) ....................................................................... ........................................................................................... 0.005 mm (0.0002 inch) Taper (MAX) ..... .............................................................................................................................................................. ............ 0.003 mm (0.0001 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1537 Crankshaft: Service and Repair CRANKSHAFT REMOVAL 1. Remove the vibration damper (1). 2. Remove the rear oil seal retainer. 3. Remove the oil pan. 4. Remove the oil pump pickup. 5. Remove the windage tray/oil pan gasket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1538 6. Remove the timing chain cover. 7. Remove the oil pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1539 8. Remove the timing drive (2). 9. Identify rod bearing caps before removal. Remove rod bearing caps with bearings. 10. Identify main bearing caps (1) before removal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1540 11. Remove main bearing caps (1) and bearings one at a time. 12. Remove the thrust washers. 13. Remove the crankshaft out of the block. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1541 1. Select the proper main bearings. 2. Install main bearings in block and caps, and lubricate bearings. 3. Position the crankshaft into the cylinder block. 4. Install the thrust washers (1). NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1542 5. Clean and oil all cap bolts. Install all main bearing caps (1). Install all cap bolts and alternately tighten in two steps using the following sequence. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1543 6. ^Step 1 - 27 Nm (20 ft. lbs.) torque. 7. ^Step 2 - Turn main cap bolts an additional 90°. 8. Install the crossbolts with new washer/gasket. Starting with crossbolt A torque each crossbolt to 28 Nm (21 ft. lbs.) torque. 9. Repeat crossbolt torque procedure. 10. Measure crankshaft end play. 11. Position the connecting rods onto the crankshaft and install the rod bearing caps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1544 12. Install timing drive (2). 13. Install oil pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1545 14. Install the timing chain cover (1). 15. Install the rear main seal and retainer. 16. Install the windage tray/oil pan gasket. 17. Install the oil pick up tube. 18. Install the oil pan. 19. Install the vibration damper. 20. Install the engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation HEATER - ENGINE BLOCK DESCRIPTION WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS. An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L/4.7L gas powered engines have the block heater located to the rear on the right side of the engine. The 5.9L diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (1). OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1549 Engine Block Heater: Testing and Inspection DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1550 Engine Block Heater: Service and Repair ENGINE BLOCK HEATER REMOVAL GAS ENGINES 1. Disconnect the battery negative cable. 2. Drain the coolant. 3. Remove the power cord from the heater by unplugging. 4. Loosen (but do not completely remove) the screw at center of block heater. 5. Remove the block heater by carefully prying from side-to-side. Note the direction of the heating element coil (up or down). The element coil must be installed correctly to prevent damage. INSTALLATION 1. Clean and inspect the block heater hole. 2. Install the new O-ring seal(s) to heater. 3. Insert the block heater into cylinder block and position the element properly. 4. With the heater fully seated, tighten center screw to 2 Nm (17 inch lbs.). 5. Fill the cooling system with the recommended coolant. 6. Start and warm the engine. 7. Check the block heater for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Vibration Damper Bolt ......................................................................................................................... ............................................... 176 Nm (129 ft. Lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1554 Harmonic Balancer - Crankshaft Pulley: Service and Repair DAMPER - CRANKSHAFT REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Drain cooling system. 4. Remove radiator upper hose. 5. Remove fan shroud. 6. Remove crankshaft damper bolt. 7. Remove damper using Special Tools 8513A Insert and 1023 Three Jaw Puller. INSTALLATION CAUTION: To prevent severe damage to the Crankshaft, Damper or Special Tool 8512-A, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 1. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft. 2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first (2). Then the roller bearing (1) is placed onto the threaded rod (3) The hardened bearing surface of the bearing (1) MUST face the nut (2). Then the hardened washer (5) slides onto the threaded rod (3). Once assembled coat the threaded rod's threads with Mopar(R) Nickel Anti-Seize or (Loctite No. 771). 3. Using Special Tool 8512-A, press damper onto crankshaft. 4. Install then tighten crankshaft damper bolt to 176 Nm (129 ft. lbs.). 5. Install radiator upper hose. 6. Install accessory drive belt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1555 7. Refill cooling system. 8. Connect negative cable to battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications PISTONS Clearance ........................................................................................................................................................... 0.0215 - 0.0485 mm (0.0008 - 0.0019 inch) Measured at 38.0 mm (1.5 inch) Below Deck Ring Groove Diameter Groove #1 ............................................................................................................................................ ..................... 89.6 - 89.8 mm (3.527 - 3.535 inch) Groove #2 ............................................................ ..................................................................................................... 88.1 - 88.3 mm (3.468 - 3.476 inch) Weight ................................................................................................................................................. .......................................... 413 grams (14.56 ounces) Piston Length ................................................. .................................................................................................................... 54.70 - 55.30 2.153 2.177 inch) Ring Groove Width No. 1 .................................................................................................................................................... ....................... 1.51 - 1.54 mm (0.0594 - 0.0606 in No. 2 .................................................................... .................................................................................................. 1.51 - 1.53 mm (0.0594 - 0.0602 inch) No. 3 ........................................................................................................................................... ....................... 3.030 - 3.055 mm (0.1192 - 0.1202 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1559 Piston: Description and Operation PISTON & CONNECTING ROD DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a "fractured cap" design. A pressed fit piston pin is used to attach the piston and connecting rod. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures STANDARD PROCEDURE - PISTON FITTING 1. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (0.0001 inch) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. 2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B. 3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank (odd numbered) and the right cylinder bank (even numbered) and must not be interchanged. 4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (0.0001 inch) increments is required. 5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1562 Piston: Removal and Replacement PISTON & CONNECTING ROD REMOVAL 1. Disconnect negative cable from battery. 2. Remove the following components: ^ Oil pan and gasket/windage tray. ^ Cylinder head covers. ^ Timing chain cover. ^ Cylinder head(s). 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing piston from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1563 4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur 6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces. 7. Carefully remove piston rings from piston(s), starting from the top ring down. CLEANING CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly. INSPECTION Check the connecting rod journal for excessive wear, taper and scoring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1564 Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. INSTALLATION 1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil. 4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads. 5. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. 6. Wipe cylinder bore clean and lubricate with engine oil. 7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1565 CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. 9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 Nm (15 ft. lbs.) plus a 90° turn. 10. Install the following components: ^ Cylinder head(s). ^ Cylinder head covers. ^ Install the intake manifold. ^ Oil pan and gasket/windage tray. 11. Fill crankcase with proper engine oil to correct level. 12. Connect negative cable to battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications PISTON PINS Clearance In Piston ......................................................................................................................................... 0.009 0.018 mm (0.00035 - 0.0007 inch) Diameter ............................................................................................................................................................ 24.0 - 24.003 mm (0.9448 - 0.9449 inch) Length ................................................................................ ....................................................................................... 70.53 - 71.03 mm (2.78 - 2.80 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RINGS Ring Gap Top Compression Ring ......................................................................................................................................... 0.23 - 0.38 mm (0.0090 - 0.0149 inch) Second Compression Ring .................................................................................................................................... 0.35 - 0.60 mm (0.0137 - 0.0236 inch) Oil Control (Steel Rails) ........................................................................................................................................ 0.15 - 0.66 mm (0.0059 - 0.0259 inch) Side Clearance Top Compression Ring ....................................................................................................................................... 0.02 - 0.068 mm (0.0007 - 0.0026 inch) Second Compression Ring .................................................................................................................................. 0.02 - 0.058 mm (0.0007 - 0.0022 inch) Oil Ring (Steel Ring) ......................................................................................................................................... 0.019 0.229 mm (0.0007 - 0.0091 inch) Ring Width Top Compression Ring ..................................................................................................................................... 1.472 - 1.490 mm (0.0579 - 0.0586 inch) Second Compression Ring ................................................................................................................................ 1.472 - 1.490 mm (0.0579 - 0.0586 inch) Oil Ring (Steel Rails) ........................................................................................................................................ 0.447 0.473 mm (0.0175 - 0.0186 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1572 Piston Ring: Service and Repair RINGS - PISTON STANDARD PROCEDURE - PISTON RING FITTING Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Wipe the cylinder bore clean. 2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore. 3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder. 4. Using a feeler gauge check the ring end gap. Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 5. Measure the ring side clearance as shown make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification. 6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1573 PISTON RING SPECIFICATION CHART 7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: ^ Oil ring expander. ^ Lower oil ring side rail. ^ Upper oil ring side rail. ^ No. 2 Intermediate piston ring. ^ No. 1 Upper piston ring. 8. Install the oil ring expander. 9. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail. 10. Install No. 2 intermediate piston ring using a piston ring installer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1574 11. Install No. 1 upper piston ring using a piston ring installer. 12. Position piston ring end gaps as shown inch It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair ROCKER ARM REMOVAL 1. Remove cylinder head cover. 2. Install pushrod retaining plate (1) special tool 9070. 3. Loosen the rocker shafts using the sequence provided. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an "I". 4. Remove the rocker shafts. Note location for reassembly. CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1582 5. Remove the pushrods. Note pushrod location for reassembly. CAUTION: Do not remove the retainers from the rocker shaft. The assembly tangs (1) at the bottom of the retainers (2) can be damaged, causing the assembly tangs to break off, and get into the engine. INSTALLATION CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. 1. Install the push rods in the same order as removed. 2. Install the pushrod retaining plate (1) special tool 9070. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1583 CAUTION: Ensure that retainers (2) and rocker arms (4) are not overlapped when torquing bolts. CAUTION: Verify that pushrod is installed into rocker arm (4) and tappet correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter "I". 3. Install rocker shaft assemblies in the same order as removed. 4. Tighten the rocker shaft bolts to 22 Nm (195 inch lbs.) torque, using the sequence provided. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1584 5. Remove pushrod retaining plate (1) special tool 9070. 6. Install cylinder head cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair COVER - CYLINDER HEAD REMOVAL 1. Disconnect battery negative cable. 2. Disconnect coil on plug connectors (4). CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only. 3. Remove cylinder head cover retaining bolts, and ground straps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1588 4. Remove cylinder head cover (1). NOTE: The gasket (2) may be used again, provided no cuts, tears, or deformation has occurred. INSTALLATION CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: DO NOT allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1589 1. Clean cylinder head cover (1) and both sealing surfaces (1,4,). Inspect and replace gasket (2) as necessary. 2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location and install left and right ground straps. CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only. NOTE: The right hand ground strap is located on the front inboard stud. The left hand ground strap is located on the rear inboard stud. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1590 3. Tighten cylinder head cover bolts and double ended studs to 8 Nm (70 inch lbs.). Begin torque sequence in the middle of head cover and torque bolts moving outward in a crisscross pattern from top to bottom. 4. Install ignition coil on plug (5), and torque fasteners (6) to 12 Nm (105 inch lbs.). 5. Connect, ignition coil electrical connectors (4). 6. Install PCV hose. 7. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair SPRINGS - VALVE REMOVAL 1. Disconnect negative battery cable. 2. Remove air cleaner assembly. 3. Remove air intake resonator. 4. Remove spark plug cables. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1594 5. Remove ignition coil connectors (4). 6. Remove ignition coils (5). 7. Remove one spark plug. 8. Remove cylinder head cover (1) using the sequence shown. CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be serviced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1595 NOTE: If removing intake valve spring, install special tool#9070, pushrod retaining plate (1), to retain the intake pushrods (2). 9. Remove exhaust/intake rocker arm shafts using the sequence shown. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1596 10. Install rocker arm shaft (1) special tool#9065. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1597 11. Install spring compressor (1,3,), special tool#9065, and exhaust adapter arm (1) tool #9065 if needed. NOTE: All valve springs and seals are removed in the same manner. 12. Insert air hose (1) into spark plug hole and charge cylinder with air. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks. 13. Compress valve spring with valve spring compressor (3) tool #9065 and remove valve retainer locks. 14. Release spring compressor (3) and remove valve spring. NOTE: The valve springs are interchangeable between intake and exhaust. 15. Remove valve seal. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1598 1. Install valve seal. 2. Install valve spring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1599 3. Using special tool#9065 (1,3,), compress valve spring and install valve spring retainer and locks. 4. Release air charge in cylinder (1). 5. Remove spring compressor tool #9065 (3). CAUTION: Verify that the pushrods are fully seated into lifter and rocker arm. Recheck after rocker arm shaft has been torqued to specification. 6. Install rocker arm shaft and pushrods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1600 7. Tighten the rocker shaft bolts to 22 Nm (195 inch lbs.) torque, using the rocker shaft torque sequence. 8. Remove special tool #9070, pushrod retaining plate (1), if used. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1601 9. Install cylinder head cover (1). 10. Tighten cylinder head cover bolts and double ended studs. 11. Install spark plugs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1602 12. Install ignition coil on plug (5), and torque fasteners (6) to 12 Nm (105 inch lbs.). 13. Install ignition coil connectors (4). 14. Install spark plug cables. 15. Install air intake resonator. 16. Install air cleaner assembly. 17. Connect negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications VALVE TIMING Intake Opens (BTDC) ..................................................................................................................................... ....................................................................... 7.0° Closes (ATDC) ..................................................... ................................................................................................................................................... 253.0° Exhaust Opens (BTDC) ..................................................................................................................................... ...................................................................... 233° Closes (ATDC) ..................................................... ........................................................................................................................................................ 27° Duration ........................................................................................................................................ ......................................................................... 253.70° Valve Overlap .............................................. .............................................................................................................................................................. ... 34° Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1606 Valve: Description and Operation VALVES & SEATS - INTAKE/EXHAUST DESCRIPTION - VALVE GUIDES The valve guides are made of powered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads. DESCRIPTION Both the intake and exhaust valves are made of steel. The intake valve is 50.93 mm (2.00 inches) in diameter and the exhaust valve is 39.53 mm (1.55 inches) in diameter. All valves use three bead lock keepers to retain the springs and promote valve rotation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation VALVES & SEATS - INTAKE/EXHAUST REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring Compressor Tool special tool #C-3422and adapter 8464. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. INSTALLATION 1. Clean valves thoroughly. Discard burned, warped and cracked valves. 2. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 3. Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. 4. Coat valve stems with lubrication oil and insert them in cylinder head. 5. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 6. Install new seals on all valve guides. Install valve springs and valve retainers. 7. Compress valve springs with Valve Spring Compressor Tool special tool #C-3422 and adapter 8464, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. 8. Install cylinder head Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1609 Valve: Service and Repair Refacing Valves & Seats STANDARD PROCEDURE- REFACING NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 inch). 2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone. 3. When the seat is properly positioned the width of the intake seat must be 1.018 - 1.62 mm (0.0464 - 0.0637 inch) and the exhaust seat must be 1.48 - 1.92 mm (0.058 - 0.075 inch). 4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 46.0 mm (1.81 inch). VALVE FACE AND VALVE SEAT ANGLE CHART 5. The valve seat must maintain an angle of 44.5 - 45.0 degrees angle. 6. The valve face must maintain a face angle of 45.0 - 45.5 degrees angle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications TORQUE-SPECIFICATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1614 Drive Belt: Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1615 Drive Belt: Testing and Inspection BELT - DRIVE DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS NOTE: 5.9L Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1616 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1617 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1618 Drive Belt: Service and Repair BELT - DRIVE REMOVAL 5.7L ENGINE 1. Remove the air intake tube between intake manifold and air filter assembly.. 2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys. 3. Remove belt. 4. Gently release tensioner. INSTALLATION NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Position the drive belt over all pulleys except for the water pump pulley. 2. Rotate tensioner counterclockwise and slip the belt over the water pump pulley. 3. Gently release tensioner. 4. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Bolt - Automatic Belt Tensioner to Block ................................................................................................................................................ 41 Nm (30 ft. lbs.) Bolt - Automatic Belt Tensioner Pulley .................................................................................................................................................... 61 Nm (45 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1622 Drive Belt Tensioner: Description and Operation TENSIONER-BELT DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1623 Drive Belt Tensioner: Service and Repair TENSIONER-BELT 5.7L ENGINE REMOVAL 1. Remove accessory drive belt. 2. Remove tensioner and mounting bracket. 3. Remove the tensioner assembly from the mounting bracket. INSTALLATION 1. Install tensioner on to the mounting bracket. Tighten bolt to 41 Nm (30 ft. lbs.). 2. Install tensioner and bracket assembly 3. Install accessory drive belt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation Engine Mount: Description and Operation COVER - STRUCTURAL DESCRIPTION The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine. OPERATION The structural cover provides additional powertrain stiffness and reduces noise and vibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount MOUNT - FRONT REMOVAL 2WD 1. Disconnect negative battery cable. 2. Raise vehicle. 3. Remove engine mount through bolts. 4. Raise engine using engine support fixture special tool #8534. 5. Remove engine mount to insulator bolts (1). 6. Remove insulator (2) from engine. 4WD Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1629 1. Disconnect the negative cable from the battery. 2. Raise the vehicle. 3. Remove the skid plate. 4. Remove the front crossmember. 5. Remove the engine oil filter. 6. Support the engine using engine support fixture, special tool #8534. 7. Support the front axle with a suitable jack. 8. Remove the (4) bolts that attach the engine mounts to the front axle. 9. Remove the (3) bolts that attach the front axle to the left engine bracket. 10. Lower the front axle. 11. Remove the (6) through bolts 12. Raise the engine far enough to be able to remove the left (4) and right (8) engine mounts. 13. Remove the engine mounts (4,8). INSTALLATION 2WD 1. Install insulator (2) on the engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1630 NOTE: For mount to engine block and left engine bracket to front axle bolts, apply Mopar(R) Lock and Seal Adhesive, Medium Strength Threadlocker. 2. Install upper and lower mount mounting bolts. Tighten bolts to 61 Nm (45 ft. lbs.). 3. Lower the engine using engine support fixture special tool #8534. 4. Install mount through bolts. 5. Tighten through bolts on both sides to 61 Nm (45 ft. lbs.). 6. Lower vehicle. 7. Connect negative battery cable. 4WD NOTE: For mount to engine block and left engine bracket to front axle bolts, apply Mopar(R) Lock and Seal Adhesive, Medium Strength Threadlocker. 1. Install the right (8) and left (4) side engine mounts to the front axle. Torque nuts to 94 Nm (70 ft. lbs.). 2. Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 Nm (70 ft. lbs.). 3. Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts. 4. Lower the engine using engine support fixture special tool #8534, until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots. 5. Loose assemble the 3 bolts that attach the front axle to the left engine bracket. 6. Loose assemble the lower through bolts. 7. Torque the nuts for the 4 through bolts to 101 Nm (75 ft. lbs.). 8. Torque the 3 bolts that attach the front axle to the left engine bracket to 101 Nm (75 ft. lbs.). 9. Install the engine oil filter, if removed. 10. Install the front crossmember. 11. Install the skid plate. 12. Lower the vehicle. 13. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1631 Engine Mount: Service and Repair Rear Mount MOUNT - REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Using a suitable jack, support transmission. 3. Remove the nuts from the transmission mount. 4. Remove the two bolts that attach the transmission mount to the engine bracket. 5. Raise the transmission enough to remove the mount from the crossmember. 6. Remove the mount. INSTALLATION NOTE: Threadlocking compound must be applied to the bolts before installation. 1. Install the two bolts that attach the transmission mount to the transmission bracket. 2. Torque the bolts to 61 Nm (45 ft. lbs.) torque. 3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember. 4. Install the nuts onto the transmission mount studs through the crossmember access slot. 5. Torque the nuts to 54 Nm (40 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1632 Engine Mount: Service and Repair Structural Collar/Cover COVER - STRUCTURAL REMOVAL 1. Raise vehicle on hoist. CAUTION: On manual transmission vehicles, the 7/16 inch engine block to clutch housing bolts must be loosened before removal of the structural dust cover (1). Clutch housing distortion will occur if this procedure is not followed. 2. Remove the bolts retaining structural cover (1,2). 3. Remove the structural cover. INSTALLATION AUTOMATIC TRANSMISSION CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover. 1. Position the structural cover in the vehicle. 2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1633 4. Torque the (4) structural dust cover bolts that go into the transmission to 6 - 11 Nm (50 - 100 inch lbs.). 5. Torque the (4) structural dust cover bolts that go into the engine block to 6 - 11 Nm (50 - 100 inch lbs.). 6. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 Nm (40 ft. lbs.), then tighten bolts (2) and (3) to 54 Nm (40 ft. lbs.) in the sequence shown. 7. Install the exhaust pipe on left hand exhaust manifold. 8. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20 - 26 Nm (15 - 20 ft. lbs.). MANUAL TRANSMISSION CAUTION: The 7/16 inch engine block to clutch housing bolts must be loosened before removal/installation of the structural dust cover. Clutch housing distortion will occur if this procedure is not followed. 1. Position the structural cover in the vehicle. CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover, and engine noise. 2. Install all bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against the corner formed by the engine and the transmission clutch housing during tightening sequence. Failure to do so may cause damage to the cover and engine noise. 4. Torque the (2)structural dust cover bolts that go into the clutch housing to 6 - 11 Nm (50 - 100 inch lbs.). 5. Torque the (4) structural dust cover bolts that go into the engine block to 6 - 11 Nm (50 - 100 inch lbs.). 6. Torque the structural cover bolt that is closest to the rear face of block on the passenger side of block to 54 Nm (40 ft. lbs.). 7. Torque the structural cover bolt that is closest to the front face of block on the drivers side to 54 Nm (40 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1634 8. Torque the remaining (2) structural cover bolts that go into the block in an "X" pattern to 54 Nm (40 ft. lbs.). 9. Torque the structural cover bolts that go into the clutch housing to 54 Nm (40 ft. lbs.). 10. Torque the 7/16 inch engine block to clutch housing bolts to 68 Nm (50 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Bolt - Idler Pulley ................................................................................................................................. .................................................... 54 Nm (40 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE At Curb Idle Speed (MIN) .................................................................................................................... ..................................................... *25 kPa (4 psi) @ 3000 rpm .......................................................... ................................................................................................................. 170 - 758 kPa (25 - 110 psi) * CAUTION: If pressure is zero at curb idle, DO NOT run engine Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1642 Engine Oil Pressure: Testing and Inspection LUBRICATION DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE 1. Remove oil pressure sending unit and install gauge assembly C-3292. 2. Run engine until thermostat opens. 3. Oil Pressure: ^ Curb Idle - 25 kPa (4 psi) minimum ^ 3000 rpm - 170 - 758 kPa (25 - 110 psi) 4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1647 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1648 Engine Oil: Technical Service Bulletins Engine - Oil Quality/Viscosity Requirements NUMBER: 09-013-04 GROUP: Engine DATE: August 6, 2004 SUBJECT: Gasoline Engine Oil Quality And Viscosity Grades MODELS: 2005 (ND) Dakota 2005 (CS) Pacifica 2005 (DR) Ram Truck 2005 (HB) Durango 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2005 (PL) Neon 2005 (PT) PT Cruiser 2005 (RS) Town & Country/ Caravan/Voyager 2005 (TJ) Wrangler 2005 (WK) Grand Cherokee NOTE: This information applies to U.S. and Canada markets only. NOTE: For additional information and vehicles not covered by this Service Bulletin refer to the service information or the Owner Manual. DISCUSSION: This bulletin involves the engine oil to be used to service Chrysler Group gasoline engines. This symbol, found on the front of the container, means that the oil quality has been certified by the American Petroleum Institute (API) (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1649 Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. MS-6395 contains requirements, not addressed by API Certification, that provide additional protection for Chrysler Group engines. All Chrysler Group gasoline engines, irrespective of model year, should be serviced with API Certified engine oils meeting MS-6395. Chrysler Group Engines are developed, certified and filled with engine oil of the designated viscosity grade, meeting MS-6395, and should be serviced with the correct viscosity grade engine oil. The following table contains the correct viscosity grades for the 2005 model year. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ..................................................... 6.6Liters (7.0 Qt) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1652 Engine Oil: Fluid Type Specifications This information has been updatad by TSB 09-013-04 API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified. MOPAR provides engine oils, that meet or exceed this requirement. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. For 3.7L/4.7L engines SAE 5W-30 engine oil is recommended for all operating temperatures. For 5.7L engines SAE 5W-20 engine oil is recommended for all operating temperatures.These engine oils improve low temperature starting and vehicle fuel economy. Refer to your engine oil filler cap for the recommended engine oil viscosity for your vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Engine Oil: Initial Inspection and Diagnostic Overview DIAGNOSIS AND TESTING - ENGINE OIL LEAK Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed: 1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak. 2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. 3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair defect. 4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not positively identified at this time, proceed with the air leak detection test method. Air Leak Detection Test Method 1. Remove the PCV valve from the IAFM. Cap or plug the PCV valve grommet. 2. Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure. 3. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair defect. 4. If the leakage occurs at the rear oil seal area, refer to Inspection for Rear Seal Area Leak. 5. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve. 6. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1655 Engine Oil: Component Tests and General Diagnostics INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. 4. If no leaks are detected, pressurize the crankcase as outlined in the, Inspection (Engine oil Leaks in general). CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Page 1656 Engine Oil: Service and Repair OIL STANDARD PROCEDURE - ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm (25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair FILTER - ENGINE OIL REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. Daimler/Chrysler Corporation recommends a Mopar(R) or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter (3). 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket (2) with engine oil. 2. Thread filter (3) onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Tighten the mounting bolts to ........................................................................................................................................................ 12 Nm (105 inch lbs.). Use the sequence above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1663 Oil Pan: Service and Repair PAN - ENGINE OIL REMOVAL 1. Disconnect the negative battery cable. 2. Install engine support fixture special tool #8534. Do not raise engine at this time. 3. For 2WD vehicles, Remove both engine mount to frame through bolts. 4. For 4WD vehicles, Loosen both left and right side engine mount bracket to mount bolts, and remove the lower bolt on each side. The upper hole in the engine bracket is slotted. 5. Remove the structural dust cover (1). 6. Drain engine oil. 7. Remove the front crossmember. CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold. 8. Raise engine using special tool #8534 to provide clearance to remove oil pan. 9. Remove the nuts from the transmission mount to crossmember. 10. Using suitable transmission jack, raise the transmission approximately 3 inches off of the crossmember. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1664 11. Remove the oil pan mounting bolts using the sequence above, and remove oil pan. NOTE: The double ended oil pan studs must be installed in the same location that they were removed from. 12. Unbolt oil pump pickup tube and remove tube. NOTE: When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused. 13. Discard the integral windage tray and gasket and replace. INSTALLATION 1. Clean the oil pan gasket mating surface of the block and oil pan. NOTE: Mopar(R) Engine RTV must be applied to the 4 T-joints, (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations. 2. Apply Mopar(R) Engine RTV at the 4 T-joints. NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old gasket cannot be reused. 3. Install a new integral windage tray and gasket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1665 4. Reinstall the oil pump pickup tube with new O-ring. Tighten tube to pump fasteners to 28 Nm (250 inch lbs.). NOTE: The double ended oil pan studs must be installed in the same location that they were removed from. 5. Position the oil pan and install the mounting bolts and studs. Tighten the mounting bolts to 12 Nm (105 inch lbs.), using the sequence above. 6. Lower the transmission onto the crossmember. Install nuts, and tighten. 7. Lower the engine into mounts using special tool #8534. 8. For 2WD vehicles, Install both the left and right side engine mount through bolts. Tighten the nuts to 68 Nm (50 ft. lbs.). 9. For 4WD vehicles, Install both the left and right side engine mount bracket to mount bolts. Tighten the nuts to 68 Nm (50 ft. lbs.). 10. Remove special tool #8534. 11. Install the structural dust cover (1). 12. Install the front crossmember. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1666 13. Fill engine oil. 14. Reconnect the negative battery cable. 15. Start engine and check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "100" psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT-10 the oil pressure gauge graphics are black against a white field except for two red graduations at the low end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT-10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT-10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduations (except SRT-10) or to the red zone (SRT-10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1690 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 Switch-Oil Pressure (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE At Curb Idle Speed (MIN) .................................................................................................................... ..................................................... *25 kPa (4 psi) @ 3000 rpm .......................................................... ................................................................................................................. 170 - 758 kPa (25 - 110 psi) * CAUTION: If pressure is zero at curb idle, DO NOT run engine Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1700 Engine Oil Pressure: Testing and Inspection LUBRICATION DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE 1. Remove oil pressure sending unit and install gauge assembly C-3292. 2. Run engine until thermostat opens. 3. Oil Pressure: ^ Curb Idle - 25 kPa (4 psi) minimum ^ 3000 rpm - 170 - 758 kPa (25 - 110 psi) 4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Description and Operation Oil Temperature Gauge: Description and Operation An oil temperature gauge (1) is standard equipment on all SRT-10 models. This electronic, analog gauge is located in the lower end of the left A-pillar trim molding below the grab handle (2), in clear view of the vehicle operator. The gauge dial face is visible through a clear plastic lens, which is secured to the gauge housing with a silver anodized trim ring. The remainder of the gauge, including the mounting provisions and the electrical connections, are concealed behind the left A-pillar trim molding. The molded plastic housing at the rear of the gauge protects the electronic circuitry of the gauge and has two mounting studs, which are secured by nuts to a molded plastic mounting bracket screwed to the back of the A-pillar trim molding. A short pigtail wire with a connector extends from the back of the gauge housing and connects the gauge to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The oil temperature gauge consists of a movable gauge needle or pointer with a 270 degree sweep that is controlled by the electronic gauge circuitry. The gauge overlay reads left-to-right from "60" to "150" with "° C" indicated directly below the low (left) end of the scale in markets where a metric instrument cluster is specified, or from "140" to "300" with "° F" indicated directly below the left end of the scale for all other markets. The text "OIL TEMP" is imprinted on the center of the gauge overlay below the hub of the gauge needle, while the text "SRT" is imprinted above the hub of the gauge needle. The gauge graphics are black against a silver field except for a single red zone at the high (right) end of the gauge scale and are clearly visible in daylight. General illumination lighting for the gauge is provided by a Light Emitting Diode (LED) that is soldered onto the gauge circuit board. The gauge overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with the gauge dial face and graduations, but this layer is also translucent. The underlying layer of the overlay is opaque and allows light from the LED on the circuit board behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. When illuminated from behind by the panel lamps dimmer controlled gauge lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Description and Operation > Page 1704 The oil temperature gauge cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The gauge illumination LED unit is not available for service replacement and, if damaged or faulty, the entire gauge must be replaced. The oil temperature gauge gives an indication to the vehicle operator of the engine oil temperature. This gauge is controlled by its own internal electronic circuit board based upon a hard wired input received by the gauge from an oil temperature sensor (4) installed in a tapped hole that penetrates an oil passage on the right side of the engine block (2) just behind the oil pressure sensor (3). The oil temperature sensor is a Negative Temperature Coefficient (NTC) thermistor that changes its internal resistance with changes in temperature. The sensor has two terminals. One terminal receives a hard wired ground path through a take out and connector of the engine wire harness (1), and the second terminal provides a variable output to the gauge through the same take out and connector. As the oil temperature increases the resistance of the sensor decreases, and as the oil temperature decreases the resistance of the sensor increases. The oil temperature gauge is an air core magnetic unit. The gauge pigtail wire and connector provides the gauge electronic circuit board with a hard wired ground path, battery current through a fused ignition switch output (run-start) circuit, a Pulse Width Modulated (PWM) panel lamps dimmer input from the instrument cluster for general illumination, and the input from the oil temperature sensor. This gauge is only operational when the ignition switch is in the On or Start positions. The gauge electronic circuit board reads the input from the oil temperature sensor, then provides linear positioning of the gauge needle on the gauge scale based upon that input. The gauge electronics will move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The oil temperature gauge and the oil temperature sensor may be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Description and Operation > Page 1705 Oil Temperature Gauge: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired oil temperature gauge and gauge lighting circuits may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When testing the oil temperature gauge by alternately opening and shorting the oil temperature sensor signal circuit, the gauge pointer may rotate in either direction (clockwise or counterclockwise) to reach the objective point on the gauge scale. This is a normal condition as the gauge electronics are programmed to move the pointer from its current position to the objective position in the direction that provides the shortest pointer travel distance. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Description and Operation > Page 1706 Oil Temperature Gauge: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim molding (5) from the inside of the left A-pillar. 3. Remove the two nuts (2) that secure the oil temperature gauge (4) mounting studs to the mounting bracket (1) on the back of the A-pillar trim. 4. Remove the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. 5. Remove the mounting bracket from the back of the A-pillar trim. 6. Push the gauge and the gauge pigtail wire (6) and connector out through the mounting hole on the face of the A-pillar trim. INSTALLATION 1. Position the oil temperature gauge (4) into the mounting hole on the face of the A-pillar trim (5). 2. Position the mounting bracket (1) to the back of the A-pillar trim with the gauge pigtail wire (6) and connector routed between the two lower mounting bracket screw bosses on the back of the A-pillar trim. 3. Install and tighten the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. Tighten the screws to 1 N.m (9 in.lbs.). 4. Align and insert the two mounting studs on the back of the gauge housing through the appropriate holes in the mounting bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Description and Operation > Page 1707 5. Install and tighten the two nuts that secure the gauge mounting studs to the mounting bracket. Tighten the nuts to 0.5 N.m (5 in.lbs.). 6. Reinstall the trim molding onto the inside of the left A-pillar. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Testing and Inspection Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold retaining bolts Tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to ............................................................................................................................. ...................................... 12 Nm (105 inch lbs.) Throttle Body-Bolts .............................................................................................................................. .............................................. 12 Nm (105 inch lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1714 Intake Manifold: Description and Operation MANIFOLD - INTAKE DESCRIPTION The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1715 Intake Manifold: Testing and Inspection DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water at the suspected leak area. 3. If a change in RPM is observed the area of the suspected leak has been found. 4. Repair as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1716 Intake Manifold: Service and Repair MANIFOLD - INTAKE REMOVAL 1. Disconnect negative cable from battery. 2. Remove resonator assembly and air inlet hose. 3. Disconnect electrical connectors for the following components: ^ Manifold Absolute Pressure (MAP) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Throttle Position (TPS) Sensor ^ Coolant Temperature (CTS) Sensor 4. Disconnect brake booster hose and Positive Crankcase Ventilation (PCV) hose. 5. Remove generator and set aside. NOTE: It is not necessary to remove lines or remove freon from A/C compressor. 6. Remove air conditioning compressor and set aside.. 7. Bleed fuel system. 8. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts. 9. Remove intake manifold and IAFM as an assembly. CLEANING NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced. Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry. INSPECTION 1. Inspect the intake sealing surface for cracks, nicks and distortion. 2. Inspect the intake manifold vacuum hose fittings for looseness or blockage. 3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion. INSTALLATION 1. Install intake manifold seals. 2. Position intake manifold and IAFM. 3. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to 12 Nm (105 inch lbs.). 4. Connect electrical connectors for the following components: ^ Manifold Absolute Pressure (MAP) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Throttle Position (TPS) Sensor ^ Coolant Temperature (CTS) Sensor ^ Idle Air Control (IAC) Motor 5. Install generator. 6. Install A/C compressor. 7. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose. 8. Install resonator assembly and air inlet hose. 9. Connect negative cable to battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "100" psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT-10 the oil pressure gauge graphics are black against a white field except for two red graduations at the low end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT-10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT-10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduations (except SRT-10) or to the red zone (SRT-10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Description and Operation Oil Temperature Gauge: Description and Operation An oil temperature gauge (1) is standard equipment on all SRT-10 models. This electronic, analog gauge is located in the lower end of the left A-pillar trim molding below the grab handle (2), in clear view of the vehicle operator. The gauge dial face is visible through a clear plastic lens, which is secured to the gauge housing with a silver anodized trim ring. The remainder of the gauge, including the mounting provisions and the electrical connections, are concealed behind the left A-pillar trim molding. The molded plastic housing at the rear of the gauge protects the electronic circuitry of the gauge and has two mounting studs, which are secured by nuts to a molded plastic mounting bracket screwed to the back of the A-pillar trim molding. A short pigtail wire with a connector extends from the back of the gauge housing and connects the gauge to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The oil temperature gauge consists of a movable gauge needle or pointer with a 270 degree sweep that is controlled by the electronic gauge circuitry. The gauge overlay reads left-to-right from "60" to "150" with "° C" indicated directly below the low (left) end of the scale in markets where a metric instrument cluster is specified, or from "140" to "300" with "° F" indicated directly below the left end of the scale for all other markets. The text "OIL TEMP" is imprinted on the center of the gauge overlay below the hub of the gauge needle, while the text "SRT" is imprinted above the hub of the gauge needle. The gauge graphics are black against a silver field except for a single red zone at the high (right) end of the gauge scale and are clearly visible in daylight. General illumination lighting for the gauge is provided by a Light Emitting Diode (LED) that is soldered onto the gauge circuit board. The gauge overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with the gauge dial face and graduations, but this layer is also translucent. The underlying layer of the overlay is opaque and allows light from the LED on the circuit board behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. When illuminated from behind by the panel lamps dimmer controlled gauge lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Description and Operation > Page 1724 The oil temperature gauge cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The gauge illumination LED unit is not available for service replacement and, if damaged or faulty, the entire gauge must be replaced. The oil temperature gauge gives an indication to the vehicle operator of the engine oil temperature. This gauge is controlled by its own internal electronic circuit board based upon a hard wired input received by the gauge from an oil temperature sensor (4) installed in a tapped hole that penetrates an oil passage on the right side of the engine block (2) just behind the oil pressure sensor (3). The oil temperature sensor is a Negative Temperature Coefficient (NTC) thermistor that changes its internal resistance with changes in temperature. The sensor has two terminals. One terminal receives a hard wired ground path through a take out and connector of the engine wire harness (1), and the second terminal provides a variable output to the gauge through the same take out and connector. As the oil temperature increases the resistance of the sensor decreases, and as the oil temperature decreases the resistance of the sensor increases. The oil temperature gauge is an air core magnetic unit. The gauge pigtail wire and connector provides the gauge electronic circuit board with a hard wired ground path, battery current through a fused ignition switch output (run-start) circuit, a Pulse Width Modulated (PWM) panel lamps dimmer input from the instrument cluster for general illumination, and the input from the oil temperature sensor. This gauge is only operational when the ignition switch is in the On or Start positions. The gauge electronic circuit board reads the input from the oil temperature sensor, then provides linear positioning of the gauge needle on the gauge scale based upon that input. The gauge electronics will move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The oil temperature gauge and the oil temperature sensor may be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Description and Operation > Page 1725 Oil Temperature Gauge: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired oil temperature gauge and gauge lighting circuits may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When testing the oil temperature gauge by alternately opening and shorting the oil temperature sensor signal circuit, the gauge pointer may rotate in either direction (clockwise or counterclockwise) to reach the objective point on the gauge scale. This is a normal condition as the gauge electronics are programmed to move the pointer from its current position to the objective position in the direction that provides the shortest pointer travel distance. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Description and Operation > Page 1726 Oil Temperature Gauge: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim molding (5) from the inside of the left A-pillar. 3. Remove the two nuts (2) that secure the oil temperature gauge (4) mounting studs to the mounting bracket (1) on the back of the A-pillar trim. 4. Remove the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. 5. Remove the mounting bracket from the back of the A-pillar trim. 6. Push the gauge and the gauge pigtail wire (6) and connector out through the mounting hole on the face of the A-pillar trim. INSTALLATION 1. Position the oil temperature gauge (4) into the mounting hole on the face of the A-pillar trim (5). 2. Position the mounting bracket (1) to the back of the A-pillar trim with the gauge pigtail wire (6) and connector routed between the two lower mounting bracket screw bosses on the back of the A-pillar trim. 3. Install and tighten the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. Tighten the screws to 1 N.m (9 in.lbs.). 4. Align and insert the two mounting studs on the back of the gauge housing through the appropriate holes in the mounting bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Description and Operation > Page 1727 5. Install and tighten the two nuts that secure the gauge mounting studs to the mounting bracket. Tighten the nuts to 0.5 N.m (5 in.lbs.). 6. Reinstall the trim molding onto the inside of the left A-pillar. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection Crankshaft Main Bearing Seal: Testing and Inspection SEAL - CRANKSHAFT OIL - REAR DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See Engine, for proper repair procedures of these items. 4. If no leaks are detected, pressurized the crankcase as outlined in the section, Inspection (Engine oil Leaks in general) CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Refer to - ENGINE - DIAGNOSIS AND TESTING, under the Oil Leak row, for components inspections on possible causes and corrections. See: Testing and Inspection/Non-Trouble Code Procedures/Engine Oil Leak Inspection 7. After the oil leak root cause and appropriate corrective action have been identified, Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1732 Crankshaft Main Bearing Seal: Service and Repair SEAL - CRANKSHAFT OIL - REAR REMOVAL NOTE: This procedure can be performed in vehicle. 1. If being performed in vehicle, remove the transmission. 2. Remove the flexplate. NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine. 3. Using Special Tool 8506 (1), remove the crankshaft rear oil seal (2). INSTALLATION CAUTION: The rear seal must be installed dry for proper operation. Do not lubricate the seal lip or outer edge. 1. Position the plastic seal guide (2) onto the crankshaft rear face. Then position the crankshaft rear oil seal (3) onto the guide. 2. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer (1) and C-4171 Driver Handle, with a hammer, tap the seal (3) into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1733 3. Install the flexplate. 4. Install the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair SEAL - CRANKSHAFT OIL - FRONT REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Drain cooling system. 4. Remove upper radiator hose. 5. Remove radiator shroud attaching fasteners. 6. Remove radiator cooling fan and shroud. 7. Remove crankshaft damper bolt. 8. Remove damper using Special Tools 8513A Insert (2) and 1023 Three Jaw Puller (1). 9. Using Special Tool 9071 (1), remove crankshaft front seal (2). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1737 CAUTION: The front crankshaft seal must be installed dry. Do not apply lubricant to sealing lip or to outer edge. 1. Using Special Tool 8348 and 8512A, install crankshaft front seal. CAUTION: To prevent severe damage to the Crankshaft or Damper, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 2. Install vibration damper. 3. Install radiator cooling fan and shroud. 4. Install upper radiator hose. 5. Install accessory drive belt refer. 6. Refill cooling system. 7. Connect negative cable to battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation SEALS - VALVE GUIDE DESCRIPTION The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Switch-Oil Pressure (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Testing and Inspection Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... ................................................. 122 Nm (90 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service Precautions Timing Chain: Service Precautions Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain Timing Chain: Service and Repair Timing Chain TIMING CHAIN & SPROCKETS REMOVAL 1. Disconnect battery negative cable. 2. Drain cooling system. 3. Remove Timing Chain Cover (1). 4. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and keyways as shown. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00 (2). The crankshaft keyway must be clocked at 2:00 (3). The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1780 5. Remove oil pump. 6. Retract tensioner shoe (1) until hole in shoe lines up with hole in bracket.. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1781 7. Slide a suitable pin (2) into the holes. 8. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets (2). 9. If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1782 1. If tensioner (1) assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 28 Nm (250 inch lbs.). 2. Retract tensioner (2) if required. CAUTION: The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00. 3. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 4. Place timing chain around both sprockets. 5. Lift sprockets and chain (keep sprockets tight against the chain in position as shown). 6. Slide both sprockets (2,3) evenly over their respective shafts and check alignment of timing marks. 7. Install the camshaft bolt. Tighten the bolt to 122 Nm (90 ft. lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1783 8. Remove tensioner pin. (1) Again, verify alignment of timing marks. 9. Install the oil pump. 10. Install the oil pan and pick up. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1784 11. Install the timing chain cover. 12. Refill engine oil. 13. Fill cooling system. 14. Connect battery negative cable. 15. Start engine and check for oil and coolant leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1785 Timing Chain: Service and Repair Timing Chain Cover COVER - TIMING REMOVAL 1. Disconnect the battery negative cable. 2. Remove the engine cover (1). 3. Remove air cleaner assembly. 4. Drain cooling system. 5. Remove accessory drive belt. 6. Remove fan and fan drive assembly. 7. Remove coolant bottle and washer bottle. 8. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge freon. 9. Remove A/C compressor and set aside. 10. Remove the generator. 11. Remove upper radiator hose. 12. Disconnect both heater hoses at timing cover. 13. Disconnect lower radiator hose at engine. 14. Remove accessory drive belt tensioner and both idler pulleys. 15. Remove crankshaft damper (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1786 NOTE: Do not remove the hoses from the power steering pump. 16. Remove power steering pump and set aside. 17. Remove the dipstick support bolt. 18. Drain the engine oil. 19. Remove the oil pan and pick up tube. NOTE: It is not necessary to remove water pump for timing cover removal. 20. Remove timing cover bolts and remove cover. 21. Verify that timing cover slide bushings (1) are located in timing cover. INSTALLATION 1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1787 2. Verify that the slide bushings (1) are installed in timing cover. 3. Install cover and new gasket. Tighten fasteners to 28 Nm (250 inch lbs.). NOTE: The large lifting stud is torqued to 55 Nm (40 ft. lbs.). 4. Install the oil pan and pick up tube. 5. Install the A/C compressor. 6. Install the generator. 7. Install power steering pump. 8. Install the dipstick support bolt. 9. Install the thermostat housing. 10. Install crankshaft damper. 11. Install accessory drive belt tensioner assembly and both idler pulleys. 12. Install radiator lower hose. 13. Install both heater hoses. 14. Install radiator fan shroud. 15. Install the fan and fan drive assembly 16. Install the accessory drive belt. 17. Install the coolant bottle and washer bottle. 18. Install the upper radiator hose. 19. Install the air cleaner assembly. 20. Fill cooling system. 21. Refill engine oil. 22. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain > Page 1788 23. Install the engine cover (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Description and Operation Timing Chain Tensioner: Description and Operation TENSIONER - TIMING CHAIN DESCRIPTION The timing chain tensioner is a stamped steel constant tension mechanical design. It is mounted to the front of the engine, behind the timing chain drive. OPERATION The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon covered spring steel arm presses on the timing chain maintaining the correct chain tension. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications NOTE: Always install a new gasket on timing cover. Timing Cover Install cover and new gasket. Tighten fasteners to ............................................................................................................................. .................................... 28 Nm (250 inch lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1795 Timing Cover: Service and Repair COVER - TIMING REMOVAL 1. Disconnect the battery negative cable. 2. Remove the engine cover (1). 3. Remove air cleaner assembly. 4. Drain cooling system. 5. Remove accessory drive belt. 6. Remove fan and fan drive assembly. 7. Remove coolant bottle and washer bottle. 8. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge freon. 9. Remove A/C compressor and set aside. 10. Remove the generator. 11. Remove upper radiator hose. 12. Disconnect both heater hoses at timing cover. 13. Disconnect lower radiator hose at engine. 14. Remove accessory drive belt tensioner and both idler pulleys. 15. Remove crankshaft damper (2). NOTE: Do not remove the hoses from the power steering pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1796 16. Remove power steering pump and set aside. 17. Remove the dipstick support bolt. 18. Drain the engine oil. 19. Remove the oil pan and pick up tube. NOTE: It is not necessary to remove water pump for timing cover removal. 20. Remove timing cover bolts and remove cover. 21. Verify that timing cover slide bushings (1) are located in timing cover. INSTALLATION 1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover. 2. Verify that the slide bushings (1) are installed in timing cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1797 3. Install cover and new gasket. Tighten fasteners to 28 Nm (250 inch lbs.). NOTE: The large lifting stud is torqued to 55 Nm (40 ft. lbs.). 4. Install the oil pan and pick up tube. 5. Install the A/C compressor. 6. Install the generator. 7. Install power steering pump. 8. Install the dipstick support bolt. 9. Install the thermostat housing. 10. Install crankshaft damper. 11. Install accessory drive belt tensioner assembly and both idler pulleys. 12. Install radiator lower hose. 13. Install both heater hoses. 14. Install radiator fan shroud. 15. Install the fan and fan drive assembly 16. Install the accessory drive belt. 17. Install the coolant bottle and washer bottle. 18. Install the upper radiator hose. 19. Install the air cleaner assembly. 20. Fill cooling system. 21. Refill engine oil. 22. Connect the battery negative cable. 23. Install the engine cover (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1802 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1803 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1807 Idle Speed: Description and Operation A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1812 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips(5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1813 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1822 5.7L The 5.7L engine (345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1823 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. 1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER) 3 CORRESPONDING SPARK PLUG NUMBER Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1831 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1832 Ignition Cable: Service and Repair REMOVAL Spark plug cables on the 5.7L engine are paired on cylinders 1/6, 2/3, 4/7 and 5/8. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. The cable retention clips must also be securely locked. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. If cable tray removal is necessary, release the 4 tray-to-manifold retention clips. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1837 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... .................................................... 0.045 in (1.14 mm) Torque Spark Plug Torque ............................................................................................................................... .................................... 13 +/- 2 ft.lbs. (18 +/- 3 Nm) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1838 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1839 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1840 Spark Plug: Testing and Inspection The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1841 Spark Plug: Service and Repair REMOVAL Eight of the 16 spark plugs are located under an ignition coil; the other 8 are not. If spark plug being removed is under coil, coil must be removed to gain access to spark plug. Refer to Ignition Coil Removal/Installation and observe all CAUTIONS and WARNINGS. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil (if coil removal is necessary), spray compressed air around coil base at cylinder head cover. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 5. Inspect spark plug condition. INSTALLATION 1. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into cylinder head by hand to avoid cross threading aluminum threads. To aid in installation, attach a piece of rubber hose, or an old spark plug boot to spark plug. 3. The 5.7L V-8 is equipped with torque critical design spark plugs. Do not exceed 15 ft.lbs. torque. Tighten spark plugs. Refer to torque specifications. 4. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 5. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. 6. Install ignition coil(s) to necessary spark plugs. 7. Install spark plug cables to remaining spark plugs. Remember to apply dielectric grease to inside of boots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All gauge pressure indications should be equal, with no more than 25% leakage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1845 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 7. Refer to - ENGINE SPECIFICATIONS) for the correct engine compression pressures. See: Specifications/Mechanical Specifications/Service Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Tighten water pump and mounting bolts to ........................................................................................................................................ 24 Nm (18 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1849 Water Pump: Description and Operation PUMP-WATER DESCRIPTION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1850 Water Pump: Testing and Inspection DIAGNOSIS AND TESTING - WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1851 Water Pump: Service and Repair WATER PUMP 5.7L ENGINE 1. Disconnect negative battery cable. 2. Drain coolant. 3. Remove serpentine belt. 4. Remove fan clutch assembly. 5. Remove coolant fill bottle. 6. Disconnect washer bottle wiring and hose. 7. Remove fan shroud assembly. 8. Remove A/C compressor and generator brace. 9. Remove idler pulleys. 10. Remove belt tensioner assembly. 11. Remove upper and lower radiator hoses. 12. Remove heater hoses. 13. Remove water pump mounting bolts and remove pump. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1852 1. Install water pump and mounting bolts. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 2. Install heater hoses. 3. Install upper and lower radiator hoses. 4. Install belt tensioner assembly. 5. Install idler pulleys. 6. Install A/C compressor and alternator brace. Tighten bolt and nuts to 28 Nm (21 ft. lbs.). 7. Install fan shroud assembly. 8. Connect washer bottle wiring and hose. 9. Install coolant fill bottle. 10. Install fan clutch assembly. 11. Install serpentine belt. 12. Connect negative battery cable. 13. Fill coolant. 14. Pressure test coolant system Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1858 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ....................................................... 16.2 qts. (15.4 L) Includes 1.0 qts. (0.9 L) for coolant reservoir. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1861 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant COOLANT DESCRIPTION ENGINE COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5°C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol-ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Engine Coolant > Page 1864 Coolant: Description and Operation Hoat Coolant HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/ fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/10O,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to --67.7°C (--90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1865 Coolant: Testing and Inspection DIAGNOSIS AND TESTING COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation CONTAINER-COOLANT RECOVERY-GAS ENGINES DESCRIPTION The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high temperature plastic. OPERATION The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 1869 Coolant Reservoir: Service and Repair CONTAINER-COOLANT RECOVERY REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Disconnect washer pump electrical connector. 2. Remove recovery hose (3) from radiator (4). 3. Remove the coolant container to fan shroud mounting bolts (1). 4. Tilt the container (2) backward towards the engine to disengage the mounting pin locking features and lift the container away from the fan shroud (5). INSTALLATION 1. Align the coolant container mounting pins into the slots on the fan shroud (5)and push the container onto the fan shroud. 2. Secure the container to the fan shroud with the bolts (1). Tighten to 8.5 Nm (75 inch lbs.). NOTE: Ensure that the locking feature on the mounting pins has engaged. 3. Connect the recovery hose (3) to the radiator (4). 4. Connect washer pump electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection Radiator Cooling Fan Motor: Testing and Inspection ELECTRONICALLY CONTROLLED VISCOUS FAN DRIVE NOISE NOTE: It is normal for fan noise to be louder (roaring) when: ^ Fan duty cycle high. This may occur when ambient (outside air temperature) is very high. ^ Engine loads and temperatures are high such as when towing a trailer. ^ Operating conditions where transmission temperatures may be high ^ Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a cold engine. LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation FAN DRIVE VISCOUS DESCRIPTION GAS ENGINES The thermal viscous fan drive is a silicone-fluid- filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. OPERATION A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown in. This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed. Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling. Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 1877 Fan Clutch: Service and Repair FAN DRIVE VISCOUS REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Do Not attempt to remove the fan/viscous fan drive assembly from the vehicle at this time. CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. 2. Disconnect negative battery cable from battery. 3. Remove coolant reserve/overflow container from fan shroud and lay aside. Do Not disconnect the hoses or drain coolant from the container. 4. Using Special Tool 6958, remove the fan blade/viscous fan drive assembly from the water pump by turning the mounting nut counterclockwise as viewed from the front. Threads on the viscous fan drive are RIGHT-HAND.. 5. Do Not unbolt the fan blade assembly from viscous fan drive at this time. 6. Remove the fan shroud-to-radiator mounting bolts. 7. Pull the lower shroud mounts out of the radiator tank clips. 8. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from vehicle. 9. After removing the fan blade/viscous fan drive assembly, do not place the viscous fan drive in a horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant. CAUTION: Do not remove water pump pulley-to-water pump bolts. This pulley is under spring tension. 10. Remove four bolts securing fan blade assembly to viscous fan drive. CAUTION: Some engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives. They are marked with the word REVERSE to designate their usage. Installation of the wrong fan or viscous fan drive can result in engine overheating. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 1878 NOTE: Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive. 1. Install fan blade assembly to the viscous fan drive. Tighten the bolts to 24 Nm (18 ft. lbs.) torque. 2. Position the fan shroud and the fan blade/viscous fan drive assembly to the vehicle as a complete unit. 3. Install the fan shroud. 4. Using Special Tool 6958, install the fan blade/viscous fan drive assembly to the water pump shaft. Tighten mounting nut to 50 Nm (37 ft. lbs.). 5. Install the coolant reserve/overflow container to the fan shroud. 6. Connect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 1886 Heater Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 1887 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secures the heater core bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "260"° F in all other markets. On vehicles with a diesel engine, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "245"° F in all other markets. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay directly below the left end of the gauge scale. On all models except SRT-10 the engine coolant temperature gauge graphics are black against a white field except for two red graduations at the high end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, about or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the left end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved into the red zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains in the red zone and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. On vehicles with a diesel engine, the ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation Radiator: Description and Operation RADIATOR DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. This radiator does not contain an internal transmission oil cooler. OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1895 Radiator: Testing and Inspection DIAGNOSIS AND TESTING RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through the cooling system. 1. Idle engine until operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and coolant is flowing to the radiator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER THE RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS WILL ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK. 2. Drain a small amount of coolant from the radiator until the ends of the radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If coolant is flowing past the exposed tubes, the coolant is circulating. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1896 Radiator: Service and Repair RADIATOR REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Disconnect battery negative cables. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. 2. Drain the cooling system. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter and the correct width. 3. Remove the hose clamps and hoses from radiator. 4. Remove the coolant reserve/overflow tank hose from the radiator filler neck. 5. Remove the coolant reserve/overflow tank from the fan shroud (pull straight up). The tank slips into slots on the fan shroud. 6. Unclip the power steering hoses from the fan shroud. 7. Disconnect the electrical connectors at the windshield washer reservoir tank and remove the tank. 8. Remove the fan shroud mounting bolts and pull up and out of the radiator tank clips. Position shroud rearward over the fan blades towards engine. 9. Disconnect the transmission cooler lines from the transmission cooler, then plug the transmission lines and cooler to prevent leakage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1897 10. Disconnect the power steering lines from the power steering cooler, then plug the power steering lines and cooler to prevent leakage. 11. Remove the two radiator upper mounting bolts. 12. Lift the radiator straight up and out of the engine compartment. Take care not to damage cooling fins or tubes on the radiator and oil coolers when removing. NOTE: The radiator is equipped with one alignment dowel on the bottom of the outlet tank and one retaining bracket on the front side of the inlet tank. Both features have rubber insulators attached to them that must be present. The alignment dowel fits into a hole at the bottom of the front end sheet metal vertical support post and the support bracket rests on top of the lower radiator closure tube. CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris. INSPECTION Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals. Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. INSTALLATION 1. Position the fan shroud over the fan blades rearward towards engine. 2. Install the rubber insulators to the lower radiator mounting features (alignment dowel and support bracket at the lower part of the radiator). 3. Lower the radiator into position while guiding the alignment dowel into the vertical post bracket. Position and seat the lower radiator support bracket onto the lower radiator closure tube. 4. Install the upper radiator mounting bolts. Tighten bolts to 10 Nm (90 inch lbs.). 5. Connect the lower radiator hose and install the clamp in the proper position. 6. Connect the power steering hoses to the power steering oil cooler and install the clamps. 7. Connect the transmission oil cooler lines to the transmission oil cooler and install the secondary latches. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1898 8. Position the fan shroud into the mounting clips on the radiator tanks and secure with bolts. Tighten the bolts to 8.5 Nm (75 inch lbs.). 9. Secure the power steering hoses into the clip on the lower fan shroud. 10. Install the windshield washer reservoir tank and connect the hose and electrical connector. 11. Install coolant reserve/overflow container hose(s) to radiator filler neck and secure properly with clamps. 12. Install coolant reserve/overflow container or degas container to fan shroud and tighten the bolts to 8.5 Nm (75 inch lbs.). 13. Connect upper radiator hose and install clamp. 14. Install battery negative cable. 15. Fill cooling system with coolant. 16. Operate the engine until it reaches normal operating temperature. Check cooling system fluid levels. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation CAP - RADIATOR PRESSURE DESCRIPTION All cooling systems are equipped with a pressure cap. For 5.9L engines, the pressure cap is located on top of the radiator outlet tank. For all engines, the pressure cap is located on top of the coolant degas container. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow container to be drawn through the recovery hose connecting the filler neck and reserve/ overflow container. If the vacuum valve is stuck shut, or the recovery hose is kinked, radiator hoses will collapse on cool down. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing Radiator Cap: Testing and Inspection Cooling System Pressure Relief Testing DIAGNOSIS AND TESTING RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool 7700 (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: THE WARNING WORDS, "DO NOT OPEN HOT", ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove the radiator cap at any time except for the following purposes: ^ Check and adjust antifreeze freeze point. ^ Refill the system with new antifreeze. ^ Conducting service procedures. ^ Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP DOWN, ROTATE IT COUNTER-CLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH THE COOLANT RESERVE/OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing > Page 1904 Radiator Cap: Testing and Inspection Radiator Cap Testing INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to red radiator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 1905 Radiator Cap: Service and Repair RADIATOR CAP Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester 7700 or an equivalent. Operate the tester pump to bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace the cap. Refer to the following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. CLEANING Use only a mild soap and water to clean the radiator cap. Using any type of solvent may cause damage to the seal in the radiator cap. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "260"° F in all other markets. On vehicles with a diesel engine, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "245"° F in all other markets. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay directly below the left end of the gauge scale. On all models except SRT-10 the engine coolant temperature gauge graphics are black against a white field except for two red graduations at the high end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, about or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the left end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved into the red zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains in the red zone and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. On vehicles with a diesel engine, the ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications On all engines the thermostat is closed below ............................................................................................................................................... 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1917 Thermostat: Description and Operation THERMOSTAT - ENGINE COOLANT DESCRIPTION GAS ENGINE CAUTION: Do not operate the engine without a thermostat, except for servicing or testing. The 3.7L/4.7L/5.7L engines use a pellet-type thermostat that controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. The 8.3L engine uses a movable sleeve type thermostat. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall temperature control. Coolant leakage into the pellet container will cause the thermostat to fail in the open position. Thermostats very rarely stick. Do not attempt to free a thermostat with a prying device. On the 3.7L/4.7L engine the thermostat is designed to block the flow of the coolant bypass journal by 50% instead of completely blocking the flow. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1918 This design controls coolant temperature more accurately. The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation. OPERATION 3.7L/4.7L/5.7L Engines The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1919 Thermostat: Testing and Inspection DIAGNOSIS AND TESTING THERMOSTAT ON-BOARD DIAGNOSTICS - GAS ENGINES All gasoline powered models are equipped with On-Board Diagnostics for certain cooling system components. Refer to On-Board Diagnostics (OBD) for additional information. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Description of On-Board Diagnostics If the Powertrain Control Module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. The DTC can also be accessed through the DRBIII (R) scan tool. Refer to the appropriate Powertrain Diagnostic Procedures information for diagnostic information and operation of the DRBIII (R) scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1920 Thermostat: Service and Repair THERMOSTAT REMOVAL 5.7L ENGINE WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE COOLING SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type. 1. Disconnect the negative battery cable. 2. Drain the cooling system. 3. Remove the radiator hose clamp (3) and radiator hose (4) at the thermostat housing (2). 4. Remove the thermostat housing mounting bolts (1), thermostat housing (2) and thermostat. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1921 1. Position the thermostat and housing (2) on the front cover. 2. Install thermostat housing bolts (1). Tighten the bolts (1) to 13 Nm (112 inch lbs.). 3. Install the radiator hose (4) onto the thermostat housing (2). 4. Fill the cooling system. 5. Connect negative battery cable. 6. Start and warm the engine. Check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Bolts - Thermostat Housing - All Except 5.9L Diesel ......................................................................................................................... 13 Nm (112 inch lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Tighten water pump and mounting bolts to ........................................................................................................................................ 24 Nm (18 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1928 Water Pump: Description and Operation PUMP-WATER DESCRIPTION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1929 Water Pump: Testing and Inspection DIAGNOSIS AND TESTING - WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1930 Water Pump: Service and Repair WATER PUMP 5.7L ENGINE 1. Disconnect negative battery cable. 2. Drain coolant. 3. Remove serpentine belt. 4. Remove fan clutch assembly. 5. Remove coolant fill bottle. 6. Disconnect washer bottle wiring and hose. 7. Remove fan shroud assembly. 8. Remove A/C compressor and generator brace. 9. Remove idler pulleys. 10. Remove belt tensioner assembly. 11. Remove upper and lower radiator hoses. 12. Remove heater hoses. 13. Remove water pump mounting bolts and remove pump. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1931 1. Install water pump and mounting bolts. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 2. Install heater hoses. 3. Install upper and lower radiator hoses. 4. Install belt tensioner assembly. 5. Install idler pulleys. 6. Install A/C compressor and alternator brace. Tighten bolt and nuts to 28 Nm (21 ft. lbs.). 7. Install fan shroud assembly. 8. Connect washer bottle wiring and hose. 9. Install coolant fill bottle. 10. Install fan clutch assembly. 11. Install serpentine belt. 12. Connect negative battery cable. 13. Fill coolant. 14. Pressure test coolant system Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CONVERTER - CATALYTIC DESCRIPTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter. OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1936 Catalytic Converter: Service and Repair CONVERTER - CATALYTIC 5.7L ENGINE 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove clamps and nuts (4). 5. Remove catalytic converter to exhaust manifold bolts (2) and nuts (1). 6. Remove catalytic converter assembly (3). INSTALLATION 5.7L ENGINE 1. Install catalytic converter to exhaust clamp (4) on catalytic converter (3) and position into exhaust pipe (5). 2. Make sure the alignment tang on catalytic converter (3) is fully seated in the notch on the exhaust pipe (5). 3. Install catalytic converter to exhaust manifold bolts (2) and nuts (1). 4. Tighten catalytic converter to exhaust manifold bolts (2) to 31 Nm (23 ft. lbs.). 5. Tighten catalytic converter to exhaust pipe clamp nuts (4) to 52.2 Nm (40 ft. lbs.) torque. 6. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Install manifold bolts and tighten using sequence provided to ............................................................................................................ 25 Nm (18 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1940 Exhaust Manifold: Description and Operation MANIFOLD - EXHAUST DESCRIPTION The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold. OPERATION The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1941 Exhaust Manifold: Service and Repair EXHAUST MANIFOLD REMOVAL 1. Disconnect negative battery cable. 2. Raise vehicle. 3. Remove exhaust pipe to manifold bolts. 4. Lower vehicle. 5. Install engine support fixture special tool #8534. 6. Raise engine enough to remove manifolds. CAUTION: Do not damage engine harness while raising the engine. 7. Remove heat shield. 8. Remove manifold bolts using sequence provided. 9. Remove manifold and gasket. CLEANING Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air. INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot). INSTALLATION EXHAUST MANIFOLD 1. Install manifold gasket and manifold. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1942 2. Install manifold bolts and tighten using sequence provided to 25 Nm (18 ft. lbs.). 3. Install heat shield and tighten nuts to 15 Nm (11 ft. lbs.). 4. Lower engine. CAUTION: Do not damage engine harness while lowering the engine. 5. Remove engine support fixture from engine. 6. Raise vehicle. 7. Tighten right and left side engine mount through bolts. 8. Install exhaust flange to pipe bolts. 9. Lower vehicle. 10. Connect negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Exhaust Pipe: Service and Repair Exhaust Pipe PIPE EXHAUST REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove exhaust pipe to manifold bolts, retainers and nuts. 4. Remove the clamp nuts. 5. Remove the exhaust pipe. INSTALLATION 1. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 inch) is required. 2. Position the exhaust pipe to manifold. Install the bolts, retainers and nuts. Tighten the nuts to 31 Nm (23 ft. lbs.) torque. 3. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1947 Exhaust Pipe: Service and Repair Tailpipe TAILPIPE REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect the exhaust tailpipe support hanger. 4. Remove clamps and nuts. 5. Remove the exhaust tailpipe. INSTALLATION 1. Loosely assemble exhaust tailpipe to permit proper alignment of all parts. 2. Connect the support hangers. 3. Position the exhaust tailpipe for proper clearance with the underbody parts. 4. Tighten all clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 5. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Lower the vehicle. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation HEAT SHIELDS DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1951 Heat Shield: Service and Repair HEAT SHIELDS REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1952 3. Slide the shield out around the exhaust system. INSTALLATION 1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or bolts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1953 2. Tighten the nuts and bolts 11 Nm (100 inch lbs.). 3. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair MUFFLER REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect the muffler hangers. 4. Remove clamps and nuts. 5. Remove the muffler. INSTALLATION 1. Assemble muffler and clamps loosely to permit proper alignment of all parts. 2. Connect the muffler hangers. 3. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 4. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Lower the vehicle. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation Body Control Module: Description and Operation The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1965 Body Control Module: Symptom Related Diagnostic Procedures Air Bag System AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems Diagnostic Test 1. AIRBAG WARNING INDICATOR ON WITHOUT ACTIVE TROUBLE CODES NOTE: Ensure the battery is fully charged. Turn the ignition on. Make sure that all active DTC's have been repaired before performing this procedure. With the DRBIII(R) read the WARNING LAMP STATES. Q: With no active DTCs, Does the LAMP REQ by ACM monitor show ON? YES: Go To 2 NO: Perform ORC VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test 2. REPLACE THE ORC WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER (ORC) IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. NOTE: When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected. Repair Replace the ORC. Perform ORC VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test NOTE: When reconnecting Airbag system components, the ignition must be turned off and the battery must be disconnected. Audio System Audio System Diagnosis Table Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1966 Audio System Diagnosis Table Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1967 Audio System Diagnosis Table Part 3 Of 3 Any diagnosis of the Audio system should begin with the use of a scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Chime Inoperative CHIME INOPERATIVE POSSIBLE CAUSES - Cluster Diagnostic Test 1. ACTUATE THE CHIME WITH THE DRBIII Turn the ignition on. Close the doors. With the DRBIII(R) select: Electro/Mech Cluster and actuate the Chime. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1968 Q: Does the chime sound when actuated by the DRBIII(R)? YES: If the chime operates as it should, check for other reasons that the chime is being inoperative. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Sounds With Drivers Door Open and Key Removed From Ignition CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1969 Chime Sounds With Driver Door Open Key Removed POSSIBLE CAUSES - Key-in IGN SW status - Ignition switch shorted - (G26) Key-in ignition sw sense short to ground - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1970 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: Ensure the exterior lamps turn on and off properly and are off before continuing this test. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Remove the key from the ignition switch. Q: Does the DRBIII(R) show Key-In IGN OPEN? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. KEY-IN IGN SWITCH SHORTED Disconnect the Ignition Switch connector. Q: Did the chime turn off? YES: Check the Ignition Lock Cylinder for damage. If OK replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1971 3. (G26) KEY-IN IGNITION SWITCH SENSE WIRE SHORT TO GROUND Turn ignition off. Disconnect the Ignition Switch connector. Disconnect the Cluster C3 connector. Measure the resistance of the (G26) Key-in Ignition Switch Sense circuit to ground at the Ignition Switch connector. Q: Is the resistance below 100.0 ohms? YES: Repair the (G26) Key-In Ignition Switch Sense wire for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Warning System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1972 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1973 WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired chime warning system inputs to the ElectroMechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and methods. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Programmable Communications Interface (PCI) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Key In Ignition and Drivers Door Open Chime Inoperative KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1974 Key In Ignition And Driver's Door Open Chime Inoperative POSSIBLE CAUSES - (Z42) Ground open - (G26) Key-in ignition switch open - Ignition switch - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1975 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: The driver's door ajar switch must be operational for the result of this test to be valid. Ensure that the Key is still in the Ignition Switch. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Q: Does the DRBIII(R) show Key-In IGN CLOSED? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. IGNITION SWITCH GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch connector. Turn all lights off. Measure the resistance between ground and the (Z42) Ground circuit in the ignition switch harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1976 NO: Repair the (Z42) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. IGNITION SWITCH OPEN Connect the ignition switch connector if disconnected. Turn ignition on. With the ignition switch connector connected, back jumper the (G26) Key-In Ignition Switch Sense circuit to ground at the ignition switch connector. With the DRBIII(R), enter Instrument Cluster Input/Outputs and observe the Key-In IGN SW status. Q: Does the DRBIII display Key-In IGN SW: Closed? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. KEY-IN IGNITION SWITCH SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch harness connector. Disconnect the Cluster C3 harness connector. Measure the resistance of the (G26) Key-In Ignition Switch Sense circuit between the ignition switch connector and the Instrument Cluster C3 connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1977 Q: Is the resistance below 5.0 ohms? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G26) Key-In Ignition Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Vehicle Speed Warning Chime Problem VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in cluster - Cluster Diagnostic Test 1. WITH THE DRBIII CHECK THE COUNTRY CODE SETTING NOTE: The high speed warning chime is for Gulf Coast Countries only. Turn the ignition on. With the DRBIII(R) in Miscellaneous check the Cluster country code setting. Q: Is the country code incorrect? YES: Program the correct country code. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Heater Control Illumination Inoperative A/C HEATER CONTROL ILLUMINATION INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1978 A/C Heater Control Illumination Inoperative POSSIBLE CAUSES - Faults present in the cluster (MIC) - (E16) Panel lamps driver circuit open - Bulb(s) - filament open (single-zone HVAC module only) - Cluster (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1979 - A/C Heater control Diagnostic Test 1. CHECK FOR DTCs IN THE CLUSTER (MIC) Turn the ignition on. With the DRBIII(R), read Cluster DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. TEST (E16) PANEL LAMPS DRIVER CIRCUIT USING A TEST LIGHT Turn the Headlamp switch on. Rotate the Cargo Dome switch to the full brightness setting. CAUTION: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (E16) Panel Lamps Driver circuit in the A/C Heater Control C1 harness connector. Q: Does the test light illuminate brightly? YES: (Dual-Zone Systems) Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: (Single-Zone Systems) Go To 3 NO: Go To 4 3. INSPECT THE INOPERATIVE BULB(S) Turn the ignition off. Remove the inoperative bulb(s) from the A/C Heater Control. NOTE: If necessary, hold the bulb in front of a lamp to see the filament. Inspect the bulb(s). Q: Is each inoperative bulb Ok? YES: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the inoperative bulb(s). Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1980 Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. CHECK (E16) PANEL LAMPS DRIVER CIRCUIT FOR AN OPEN Disconnect the A/C Heater Control C1 harness connector. Disconnect the Cluster C1 harness connector. Measure the resistance of the (E16) Panel Lamps Driver circuit between the A/C Heater Control C1 harness connector and the Cluster C1 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (E16) Panel Lamps Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Flashing A/C STATUS INDICATOR FLASHING Theory of Operation Running the AC Cooldown test will cause the A/C status indicator to flash. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. When the A/C status indicator is flashing, it will not indicate A/C operating status. However, the A/C mode switch will continue to function normally. For vehicles equipped with EBL, when the A/C status indicator is flashing, the EBL status indicator will not function. However, the EBL mode switch will continue to function normally. POSSIBLE CAUSES - A/C Cooldown test failed 1. PERFORM THE A/C COOLDOWN TEST NOTE: The following are prerequisites of the Cooldown Test. Verify each of the following before running the test: - Verify that no Evaporator Temperature Sensor related DTCs are not active. If active, diagnose and repair the DTC before proceeding. - Verify that the refrigerant system has an adequate charge. Check and repair as necessary before proceeding. - Verify that the blower motor operates correctly in all speeds. Diagnose and repair all blower related faults before proceeding. - Verify that the work area ambient temperature is above 21.1° C (70° F) before proceeding. Move the vehicle to a warmer work area if necessary. - Verify that the evaporator temperature is above 12.7° C (55° F) before proceeding. - Verify that the Mode Select control is set to the panel position. - Verify that the A/C compressor is not running. If the compressor is running, turn the A/C off and allow the evaporator to warm up before proceeding. Start the engine. Turn the Blower control to the high speed position. With the DRBIII(R) in HVAC, select System Tests and then select AC Cooldown test. Allow one minute for the test to complete. One or more Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1981 status messages will display on the DRBIII(R) after running the AC Cooldown Test. These messages will clear after paging back out of this test function. Therefore, it is important to note all messages before doing so. Q: Does the DRBIII(R) display a status message that indicates a fault has occurred? Yes, Blower Not On High Diagnose and repair the fault. Refer to Blower Not On High for the diagnostic test procedure. Yes, Cooldown Test Sensor Failure Diagnose and repair the fault. Refer to Cooldown Test Sensor Failure for the diagnostic test procedure. Yes, Cooldown Time Excessive Fault Diagnose and repair the fault. Refer to Cooldown Time Excessive Fault for the diagnostic test procedure. Yes, Cooldown Test Too Cold To Start Diagnose and repair the fault. Refer to Cooldown Test Too Cold To Start for the diagnostic test procedure. NO: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW A/C STATUS INDICATOR WILL NOT ILLUMINATE - A/C HEATER CONTROL WITHOUT EBL SW Theory of Operation Failing recalibration will prevent the A/C status indicator from operating but still allows the A/C mode switch to function normally. This test verifies if the status indicator is inoperable due to either a recalibration failure or a fault with the status indicator. POSSIBLE CAUSES - HVAC door recalibration failed - A/C Heater control Diagnostic Test 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Failed? YES: Diagnose and repair the fault(s). NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Dual-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1982 Actuator Circuit Test Diagnostics (Dual-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1983 messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test fault message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1984 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1985 Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1986 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1987 YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1988 Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C29) Mode Door 2 Driver circuit and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C33) Passenger Blend Door Driver circuit for a short to the (C29) Mode Door 2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 12 12. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1989 Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 13 NO: Go To 14 13. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 14. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1990 Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Single-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1991 Actuator Circuit Test Diagnostics (Single-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1992 shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1993 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1994 Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1995 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1996 NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C29) Mode Door 2 Driver circuit for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1997 Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 12 NO: Go To 13 12. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1998 YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 13. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Dual-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 1999 Blend/Mode/Recirc Door Operation Improper (Dual-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2000 - Door(s) bound up, warped, worn, damaged - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Passenger Blend Door Function Test Go To 6 Driver Blend Door Function Test Go To 7 Recirculation Door Function Test Go To 8 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2001 Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK PASSENGER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Passenger Blend control to the full hot position. Move the Passenger Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the passenger's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Passenger Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK DRIVER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Driver Blend control to the full hot position. Move the Driver Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the driver's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Driver Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Single-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2002 Blend/Mode/Recirc Door Operation Improper (Single-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open - Door(s) bound up, warped, worn, damaged Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2003 - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Blend Door Function Test Go To 6 Recirculation Door Function Test Go To 7 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2004 YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Blend control to the full hot position. Move the Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Motor Inoperative (Except SRT10) BLOWER MOTOR INOPERATIVE (EXCEPT SRT10) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2005 Blower Motor Inoperative (Except SRT10) POSSIBLE CAUSES - (C7) Blower motor feed circuit shorted to ground - (A970) Fused B(+) circuit shorted to ground - (C70) Blower motor high driver circuit open - (Z134) Ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2006 - (C7) Blower motor feed circuit open - (A970) Fused B(+) circuit open - IPM fuse #4 open - Blower motor - Ignition switch - A/C heater control Diagnostic Test 1. CHECK THE FUSE Turn the ignition off. Remove and inspect IPM Fuse #4. Q: Is the fuse open? YES: Replace IPM Fuse #4 and Go To 2. NO: Reinstall IPM Fuse #4 and Go To 5. 2. CHECK BLOWER MOTOR OPERATION Turn the ignition on. Turn the blower on and operate it in all speeds and modes. Q: Does the blower motor operate properly without blowing the fuse? YES: Check the (C7) Blower Motor Feed circuit and the (A970) Fused B(+) circuit for an intermittent short to ground. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2007 Turn the ignition off. Disconnect the Blower Motor harness connector. Measure the resistance of the (C7) Blower Motor Feed circuit between ground and the Blower Motor harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C7) Blower Motor Feed circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (A970) FUSED B(+) CIRCUIT FOR A SHORT TO GROUND Disconnect the Ignition Switch harness connector. Measure the resistance of the (A970) Fused B(+) circuit between ground and the Ignition Switch harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (A970) Fused B(+) circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor and fuse. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2008 Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Blower Motor harness connector. Q: Does the test light illuminate brightly? YES: Go To 6 NO: Go To 9 6. CHECK BLOWER MOTOR OPERATION BY BYPASSING THE A/C HEATER CONTROL Turn the ignition off. Connect a jumper wire between ground and the (C70) Blower Motor High Driver circuit in the Blower Motor harness connector. Turn the ignition on. Q: Does the blower motor run at high speed? YES: Go To 7 NO: Replace the Blower Motor. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2009 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor harness connector. Measure the resistance of the (C70) Blower Motor High Driver circuit between the A/C Heater Control C2 harness connector and the Blower Motor harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 8 NO: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (Z134) GROUND CIRCUIT FOR AN OPEN Measure the resistance of the (Z134) Ground circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the A/C Heater Control. NO: Repair the (Z134) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2010 NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Repair the (C7) Blower Motor Feed circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (A970) FUSED B(+) CIRCUIT FOR AN OPEN NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (A970) Fused B(+) circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (A970) Fused B(+) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Speed Does Not Correspond With Control Setting Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2011 BLOWER SPEED DOES NOT CORRESPOND WITH CONTROL SETTING Blower Speed Does Not Correspond With Control Setting POSSIBLE CAUSES - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2012 - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to voltage - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted together - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit open - Blower motor resistor block open - A/C heater control Diagnostic Test 1. CHECK IF THE BLOWER MOTOR RUNS WITH THE BLOWER CONTROL IN THE OFF POSITION Turn the Blower control to the Off position. Turn the ignition on. Q: Does the blower motor run? YES: Go To 2 NO: Go To 3 2. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms on any of the circuits? YES: Repair all circuits with a resistance below 10K ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2013 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Does the test light illuminate brightly on each circuit? YES: Go To 4 NO: Go To 8 4. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the voltage of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is there voltage present on any of the circuits? YES: Repair all circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: GO TO 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2014 5. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR A SHORT TO THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C71) Blower Motor Low Driver circuit and the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C71) Blower Motor Low Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C71) Blower Motor Low Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR A SHORT TO THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C73) Blower Motor M2 Driver circuit and the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C73) Blower Motor M2 Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C73) Blower Motor M2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR A SHORT TO THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2015 Measure the resistance between the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C72) Blower Motor M1 Driver circuit for a short to the (C70) Blower Motor High Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 9 NO: Repair the (C71) Blower Motor Low Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2016 Measure the resistance of the (C73) Blower Motor M2 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 10 NO: Repair the (C73) Blower Motor M2 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR AN OPEN Measure the resistance of the (C72) Blower Motor M1 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 11 NO: Repair the (C72) Blower Motor M1 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 11. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2017 Measure the resistance of the (C70) Blower Motor High Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor Resistor Block. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test EBL Status Indicator Flashing EBL STATUS INDICATOR FLASHING Theory of Operation Running the HVAC Door Recalibration will cause the EBL status indicator to flash. If recalibration fails, the status indicator will continue to flash until either the system passes recalibration or the ignition key is cycled. When the EBL status indicator is flashing, it will not indicate EBL operating status. However, the EBL mode switch will continue to function normally. When the EBL status indicator is flashing, the A/C status indicator will not function. However, the A/C mode switch will continue to function normally. POSSIBLE CAUSES - HVAC door recalibration failed 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Passed? YES: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Diagnose and repair the fault(s). Horn HORNS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2018 Horns Inoperative POSSIBLE CAUSES - DTC present - Fuse #45 - Horns - Horn ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2019 - Horn relay output circuit open - Horn switch - Horn switch ground - Clockspring - Horn switch sense open - Integrated power module - Instrument cluster - Front control module Diagnostic Test 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to symptom list. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. ACTUATE HORN RELAY With the DRBIII(R), actuate the Horn Relay. Q: Do the horns operate? YES: Go To 3 NO: Go To 7 3. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch. Measure the resistance of the Horn Switch ground circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the horn switch ground as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch connector. WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the Horn switch connector and ground. Q: Did the horns sound? YES: Replace the horn switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CLOCKSPRING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2020 Turn the ignition off. Disconnect the clockspring C1 connector. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the clockspring connector and ground. Q: Did the horns sound? YES: Replace the clockspring. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. HORN SWITCH SENSE Turn the ignition off. Disconnect the clockspring C1 connector. Disconnect the Instrument Cluster C3 connector. NOTE: Check connectors - Clean/repair as necessary. Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Instrument Cluster C3 connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Horn Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2021 7. CHECK FUSE #45 Turn the ignition off. Using a 12-volt test light connected to ground, check the Horn fuse #45 in the IPM. Q: Is the fuse open? YES: Replace the fuse. Check for a short to ground in the Horn Relay Output circuit from the IPM to the horns. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. HORN RELAY OUTPUT Disconnect a horn connector. With the DRBIII(R), actuate the Horn Relay. Using a 12-volt test light connected to ground, check the Horn Relay Output circuit. Q: Does the test light illuminate brightly? YES: Go To 9 NO: Go To 10 9. HORN GROUND CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2022 Turn the ignition off. Disconnect the Horn connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit in the horn connector. Q: Does the test light illuminate brightly? YES: Replace the Horns. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. HORN RELAY OUTPUT CIRCUIT OPEN Gain access to the IPM C1 connector. Using a 12-volt test light connected to ground, back probe the Horn Relay Output circuit in the IPM C1 connector. Turn the ignition on. With the DRBIII(R), the actuate the horn relay. Q: Does the test light illuminate brightly? YES: Repair the Horn Relay Output circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2023 11. INTEGRATED POWER MODULE Turn the ignition off. Remove the Front Control Module from the Integrated Power Module. NOTE: - Check connectors - Clean/repair as necessary. - The test light is still connected to the C1 connector. Momentarily jumper the Horn Relay Control circuit to ground at the FCM connector. Q: Does the test light illuminate brightly? YES: Replace the Front Control Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Integrated Power Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test All Gauges Inoperative ALL GAUGES INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2024 All Gauges Inoperative POSSIBLE CAUSES - No response - PCI BUS - No response - PCI BUS - powertrain control module - PCI BUS - instrument cluster - (F21) Fused ignition switch output (run/start) circuit short to ground - (F1) Fused ignition switch output (off/run/start) circuit short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2025 - (F21) Fused ignition switch output (run/start) circuit open - (F1) Fused ignition switch output (off/run/start) circuit open - (Z18) Instrument cluster ground circuit for an open - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS NOTE: Diagnose and repair any MIC, PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test. Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), select Body, MIC, SYSTEM TESTS, PCM Monitor. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PCI BUS - INSTRUMENT CLUSTER Turn the ignition on. With the DRBIII(R), select Body, MIC, MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Inspect the #20 Fuse in the PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2026 If the fuse is open, replace with proper rated fuse. Turn the ignition on for one minute. Turn the ignition off. Inspect the #20 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F21) Fused Ignition Switch Output (Unlock/Run) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. If the fuse is open, replace with the proper rated fuse. Turn the ignition on for 1 minute. Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F1) Fused Ignition Switch Output (Run/Start) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2027 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F1) Fused Ignition Switch Output (Off/Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F1) Fused Ignition Switch Output (Off/Run/ Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2028 Measure the resistance between ground and the (Z18) Instrument Cluster Ground circuit. Q: Is the resistance below 5.0 ohms? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z18) Instrument Cluster Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Any PCI Indicator Inoperative ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - Indicator message not received - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - INSTRUMENT CLUSTER With the DRBIII(R), select MIC, then MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE INSTRUMENT CLUSTER. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. NO RESPONSE - PCI BUS With the DRBIII(R), select Body, MIC, MONITORS, PCI BUS MONITORS. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE POWERTRAIN CONTROL MODULE. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. INDICATOR MESSAGE NOT RECEIVED NOTE: Diagnose and repair any PCM or BCM DTCs before proceeding with this test. Perform the Instrument Cluster Self Test. Depress and hold the Trip Odometer button while turning the ignition from the off to the on position. Observe the indicator in question. Q: Did the indicator illuminate? YES: Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2029 Brake Warning Indicator Always On BRAKE WARNING INDICATOR ALWAYS ON Brake Warning Indicator Always On POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2030 - (B20) Brake fluid level sensor sense circuit short to ground - (B25) Park brake switch sense circuit short to ground - Brake fluid level sensor - Park brake switch - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. BRAKE FLUID LEVEL SENSOR NOTE: Diagnose and repair any MIC, Brake, or Communication DTCs before proceeding with this test. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance of the Brake Fluid Level Sensor between pin 1 and pin 2. Q: Does the resistance measure less than 900 ohms? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2031 Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance between ground and the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PARK BRAKE SWITCH Turn the ignition off. Disconnect the Park Brake Switch harness connector. Turn the ignition on. Observe the Brake warning indicator. Q: Did the Brake warning indicator illuminate briefly and then turn off? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. (B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2032 Turn the ignition off. Disconnect the Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (B25) Park Brake Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. ANTI-LOCK BRAKES MODULE Turn the ignition off. Reconnect any harness connector(s) that were previously disconnected. Turn the ignition on. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Inoperative BRAKE WARNING INDICATOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2033 Brake Warning Indicator Inoperative POSSIBLE CAUSES - (Z420) Brake fluid level sensor ground circuit open - (B25) Park brake switch sense circuit open - (B20) Brake fluid level sense circuit open - Park brake switch - Brake fluid level sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2034 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. FAULT LOCATION NOTE: Diagnose and repair any MIC, ABS, or Communication DTCs before proceeding with this test. Q: Is the Brake warning indicator only inoperative using the Park Brake? YES: Go To 2 NO: Go To 4 2. PARK BRAKE SWITCH Disconnect the Park Brake Switch harness connector. Connect a jumper wire between the (B25) Park Brake Switch Sense circuit and ground. Turn the ignition on. Observe the BRAKE indicator. Q: Did the BRAKE indicator illuminate? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2035 Turn the ignition off. Disconnect the (B25) Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (B25) Park Brake Switch Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. BRAKE FLUID LEVEL SENSOR Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Q: Does the Brake warning indicator illuminate? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2036 5. (Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance between ground and the (Z420) Brake Fluid Level Sensor Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z420) Brake Fluid Level Sensor Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. (B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance of the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2037 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Anti-lock Brakes Module harness connector. Connect a jumper wire between the (B25) Brake Fluid Level Sensor Sense circuit and ground. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Fuel Gauge Inaccurate FUEL GAUGE INACCURATE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2038 Fuel Gauge Inaccurate POSSIBLE CAUSES - Fuel level sensor wiring - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2039 1. DTC PRESENT NOTE: Diagnose and repair any PCI Bus problems before proceeding with this test. Turn the ignition on. With the DRBIII(R), read the PCM DTCs. Q: Does the DRBIII(R) display any Fuel Level Sensor related DTC? YES: Refer to the Powertrain Diagnostic Information for the related symptom(s). Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test as follows: Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the Fuel Gauge during the Self Test. The Fuel Gauge pointer should pause at each of these following positions: E, 1/4, 1/2, 3/4, Full, and back to E. Q: Does the Fuel Gauge function as described above? YES: Go To 3 NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. FUEL LEVEL SENSOR WIRING Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Disconnect the PCM C2 and C3 harness connectors. Measure the resistance of the (N4) Fuel Level Sensor Signal circuit between the Fuel Pump Module harness connector and the PCM harness connector. Measure the resistance of the (K900) Sensor Ground circuit between the Fuel Pump Module harness connector and the PCM harness connector. Q: Is the resistance below 5.0 ohms on both circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2040 YES: Replace the Fuel Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the circuits with a resistance above 5.0 ohms for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Gauge Inoperative - Gas Engines ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module - Instrument cluster DIAGNOSTIC TEST 1. POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any PCM DTCs? YES: Refer to the DRIVEABILITY category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Perform the Instrument Cluster Self Test. NOTE: The Self Test can be initiated manually by depressing and holding the Trip Reset button while turning the ignition on, or by using the DRBIII(R). Observe the gauge in question while the Instrument Cluster performs the Self Test. The gauges should position at the following calibrations points: Speedometer MPH: 0, 20, 60, 90 Tachometer Gas: 0, 1000, 3000, 6000 Fuel: E, 1/4, 1/2, 3/4, F Coolant: Cold, 1/4, 1/2, 3/4, HI Volts: 6, 9, 12, 15, 17 Q: Did the gauge in question operate properly? YES: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wire harness. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test PRNDL Not Displaying Correct Position (EATX Vehicles) PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster DIAGNOSTIC TEST 1. DTC PRESENT NOTE: - Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle. - Ensure that there is communication between the Cluster and PCM before proceeding with this test. - Diagnose and repair any DTCs before proceeding with this test. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2041 - Ensure that the PCM passes the Shift Lever Test with the DRBIII(R) before proceeding with this test. Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any MIC or PCM DTCs? YES: Refer to the correct symptom list for problems related to DTCs. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test. Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the PRNDL display during the Self Test. Q: Did any part of the VF display fail to illuminate? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wiring harness, refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off SEAT BELT WARNING INDICATOR ALWAYS OFF Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2042 Seat Belt Warning Indicator Always Off POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster Diagnostic Art Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2043 1. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2044 Seat Belt Warning Indicator Always Off - Standard Cab POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2045 1. (G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on SEAT BELT WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2046 Seat Belt Warning Indicator Always On POSSIBLE CAUSES - (Z951) Seat belt switch ground circuit for an open - (G10) Seat belt switch sense circuit open - Seat belt switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2047 DIAGNOSTIC TEST 1. CHECK THE OPERATION OF THE SEAT BELT SWITCH Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate for approximately 4 seconds and then turn off? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Measure the resistance between ground and the (Z951) Seat Belt Switch Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2048 Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2049 Seat Belt Warning Indicator Always On - Standard Cab POSSIBLE CAUSES - (F983) Fused ignition switch output (run-acc) circuit open - (Z951) Seat belt switch ground circuit open - (G10) Seat belt switch sense circuit open - Seat belt tensioner reducer Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2050 - Seat belt switch - Instrument cluster 1. (F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN Turn the ignition off. Disconnect the Seat Belt Tensioner Reducer harness connector. Turn the ignition on. Measure the voltage between the (F983) Fused Ignition Switch Output (Run-Acc) circuit and ground in the Tensioner Reducer harness connector. Q: Is the voltage above 10.5 volts? YES: Go To 2 NO: Repair the (F983) Fused Ignition Switch Output (Run-Acc) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. SEAT BELT TENSIONER REDUCER Ensure that the Seat Belt Tensioner Reducer harness connector is connected. Measure the voltage between the (G10) Seat Belt Switch Sense circuit and ground in the Seat Belt Tensioner Reducer harness connector (cavity 2). Q: Is there any voltage present? YES: Go To 3 NO: Replace the Seat Belt Tensioner Reducer. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. SEAT BELT SWITCH Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2051 Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Measure the resistance between ground and the (Z951) Seat Belt Switch circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2052 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Open DRIVER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2053 Driver Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z75) driver door ajar switch ground circuit - Open (G75) driver door ajar switch sense circuit - Open driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2054 DIAGNOSTIC TEST 1. OPEN DRIVER DOOR AJAR SWITCH Disconnect the Driver Door Latch connector. Connect a jumper wire between the (G75) Sense circuit and the (Z75) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z75) DRIVER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z75) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES:Go To 3 NO: Repair the (Z75) Driver Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2055 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G75) Driver Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G75) Driver Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Shorted to Ground DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2056 Driver Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G75) Driver door ajar switch sense circuit short to ground - Driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2057 DIAGNOSTIC TEST 1. DRIVER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Driver Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G75) Driver Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G75) Driver Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2058 LEFT REAR DOOR AJAR CIRCUIT OPEN Left Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z79) left rear door ajar switch ground circuit - Open (G77) left rear door ajar switch sense circuit - Open left rear door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2059 - Instrument cluster DIAGNOSTIC TEST 1. OPEN LEFT REAR DOOR AJAR SWITCH Disconnect the Left Rear Door Latch connector. Connect a jumper wire between the (G77) Sense circuit and the Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO:Go To 2 2. OPEN (Z79) LEFT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z79) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z79) Left Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2060 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G77) Left Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Shorted to Ground LEFT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2061 Left Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G77) Left rear door ajar switch sense circuit short to ground - Left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2062 DIAGNOSTIC TEST 1. LEFT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Left Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G77) Left Rear Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2063 PASSENGER DOOR AJAR CIRCUIT OPEN Passenger Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z74) passenger door ajar switch ground circuit - Open (G74) passenger door ajar switch sense circuit - Open passenger door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2064 - Instrument cluster DIAGNOSTIC TEST 1. OPEN PASSENGER DOOR AJAR SWITCH Disconnect the Passenger Door Latch connector. Connect a jumper wire between the (G74) Sense circuit and the (Z74) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z74) PASSENGER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z74) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z74) Passenger Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2065 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G74) Passenger Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G74) Passenger Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Shorted to Ground PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2066 Passenger Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G74) Passenger door ajar switch sense circuit short to ground - Passenger door ajar switch - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2067 1. PASSENGER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Passenger Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G74) Passenger Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G74) Passenger Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Open RIGHT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2068 Right Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z72) right rear door ajar switch ground circuit - Open (G76) right rear door ajar switch sense circuit - Open right rear door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2069 - Instrument cluster DIAGNOSTIC TEST 1. OPEN RIGHT REAR DOOR AJAR SWITCH Disconnect the Right Rear Door Latch connector. Connect a jumper wire between the (G76) Sense circuit and the (Z72) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Right Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z72) RIGHT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z72) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z72) Right Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2070 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G76) Right Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Shorted to Ground RIGHT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2071 Right Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G76) Right rear door ajar switch sense circuit short to ground - Right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2072 DIAGNOSTIC TEST 1. RIGHT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Right Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Right Rear Door Ajar Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G76) Right Rear Door Ajar Switch Sense circuit and test for a short to ground. Q: Does the test light illuminate brightly? YES: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Average Fuel Economy Inaccurate or Wrong AVERAGE FUEL ECONOMY INACCURATE OR WRONG Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2073 POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. CMTC or EVIC Inoperative CMTC OR EVIC INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2074 CMTC Or EVIC Inoperative POSSIBLE CAUSES - (F21) Fused ignition switch output (run/start) circuit open - (Z13) Electronic overhead module ground circuit open - Electronic overhead module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2075 1. (F21) FUSED IGNITION RUN/START CIRCUIT OPEN NOTE: Diagnose and repair any MIC, FCM, PCM, or Communication DTCs before proceeding. Turn the ignition off. Disconnect the Electronic Overhead Module harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 0.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (Z13) ELECTRONIC OVERHEAD MODULE GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance between ground and the (Z13) Electronic Overhead Module Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z13) Electronic Overhead Module Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Compass Test Failure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2076 COMPASS TEST FAILURE WHEN MONITORED With the ignition on. SET CONDITION The Electronic Overhead Module (EOM) display reads "FAILED SELF TEST." POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Depress and hold the RESET and C/T buttons while turning the ignition on. NOTE: This test may also be performed using the DRBIII(R). Q: Does the EOM or DRBIII(R) display "FAILED SELF TEST"? YES: Replace the EOM. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Distance to Empty Inaccurate or Wrong DISTANCE TO EMPTY INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Elapsed Ignition On Time Inaccurate or Wrong ELAPSED IGNITION ON TIME INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2077 Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Temperature Display Inaccurate or Inoperative TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Electronic overhead module 1. AMBIENT TEMPERATURE SENSOR NOTE: - Diagnose and repair any FCM, EOM, PCM, or Communication DTCs before proceeding with this test. - The Ambient Temperature Sensor is hardwired to the FCM (Diesel), or to the PCM. Ambient temperature information is transmitted to the EOM via the PCI Bus. Turn the ignition off. Disconnect the Ambient Temperature Sensor harness connector. Measure the resistance of the Ambient Temperature Sensor using the following temperature/resistance values: 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.88 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms 50° C (122° F) Sensor Resistance = 3.33 - 3.88 Kilohms Q: Is the Ambient Temperature Sensor resistance measurement within the min/max specifications? YES: Go To 2 NO: Replace the Ambient Temperature Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. ELECTRONIC OVERHEAD MODULE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2078 Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Press and hold the C/T and Reset buttons. Turn the ignition on. NOTE: NOTE: The self test can also be performed using the DRBIII(R). Observe the EOM display at the conclusion of the self test. Q: Does the EOM display "Passed Self Test"? YES: Test Complete. NO: Replace and configure the EOM. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Trip Odometer Inaccurate or Wrong TRIP ODOMETER INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC VEHICLE INFORMATION CENTER NOTE: - Diagnose and repair any FIDEM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the OEM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. All Door Locks Inoperative ALL DOOR LOCKS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2079 All Door Locks Inoperative POSSIBLE CAUSES - DTC present - Fuse #22 open - (A941) Fuse B+ circuit open - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2080 Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock or Cluster related DTC's? YES: Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. FUSE #22 OPEN Test both sides of fuse #22 in the PDC. Q: Is there 12 volts on both sides of fuse #22? YES: Go To 3 NO: Replace the fuse if open and retry the system. If the fuse blows, locate and repair a short to the Instrument Cluster. The 12 volt supply to the fuse is a bus bar in the PDC. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. (A941) FUSED B+ CIRCUIT OPEN Turn the ignition off. Remove the instrument cluster. Measure the voltage between the (A941) Fused B+ circuit and ground (cavity 2 in the C1 connector to ground). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2081 Q: Is the voltage above 10.0 volts on the Fused B+ circuit? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Fused B+ circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Automatic (Rolling) Door Locks Inoperative AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Door ajar switch status incorrect - TPS or VSS DTC's - Auto door locks not enabled - Instrument cluster Diagnostic Test 1. CHECK THE DOOR AJAR SWITCH STATUS Ensure all doors are closed. With the DRBIII, enter "Electro/Mech Cluster" then "Input/Output" and observe all of the Door Ajar states. Q: Does the DRBIII display CLOSED for any door ajar state? YES: Select the appropriate Door Ajar Circuit Shorted: NO: Go To 2 2. ANY TPS OR VSS RELATED DTC'S With the DRBIII read "Engine" and "Anti-Lock Brakes" DTC's. Q: Does the DRBIII display any Throttle Position Sensor or Vehicle Speed Sensor related DTC's? YES: Diagnose and repair the DTC's. NO: Go To 3 3. ENABLE AUTO DOOR LOCKS With the DRBIII, enter "Electron/Mech Cluster" then "Miscellaneous" and observe the rolling door lock status. Q: Does the DRBIII display ROLLING DOOR LOCKS: ENABLED YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: With the DRBIII, enable the Auto Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2082 Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Cylinder Lock Switch Inoperative CYLINDER LOCK SWITCH INOPERATIVE Cylinder Lock Switch Inoperative POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2083 DTC PRESENT - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch mux circuit open - (G163) Cylinder lock switch mux wire short to ground - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Turn the ignition on. Measure the voltage between (G163) Cylinder Lock Switch Mux circuit and ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2084 Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2085 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Door Lock Inhibit Inoperative DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster Diagnostic Test 1. CHIME INOPERATIVE Turn the ignition off but leave the key in the ignition. Open the drivers door. Q: Does the chime sound? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Perform the test "KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE". See: Chime System/Key In Ignition and Drivers Door Open Chime Inoperative Driver Door Fails to Lock and Unlock DRIVER DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2086 Driver Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P1) Door unlock driver left front wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2087 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P1) Door Unlock Driver Left Front circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Driver Door lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2088 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Driver Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P1) DOOR UNLOCK DRIVER LEFT FRONT WIRE OPEN Measure the resistance of the (P1) Door Unlock Driver Left Front circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P1) Door Unlock Driver Left Front wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Fails to Lock & Unlock LEFT REAR DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2089 Left Rear Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P5) Door unlock driver left rear wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2090 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks to diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P5) Door Unlock Driver Left Rear circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the left doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2091 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Left Rear Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P5) DOOR UNLOCK DRIVER LEFT REAR WIRE OPEN Measure the resistance of the (P5) Door Unlock Driver Left Rear circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P5) Door Unlock Driver Left Rear wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Door Lock Motor Inoperative ONE DOOR LOCK MOTOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2092 POSSIBLE CAUSES - DTC's present - Door lock driver or door unlock driver circuit open - Door latch Diagnostic Test 1. CHECK DOOR LOCK MOTOR CIRCUIT With the DRBIII(R), read DTCs. If there are any door lock related DTC's, refer to symptom list for problems related to Power Door Locks and diagnose and repair the DTC's. Disconnect the inoperative Door Latch connector. Connect a 12 volt test light between the Door Lock Driver and the Door Unlock Driver circuits in the latch connector. NOTE: Graphic shows Passenger Latch - all others similar. Operate the door locks several time in the lock and unlock positions from a door lock switch and observe the test light. Q: Does the test light illuminate brightly when the locks are actuated in both directions? YES: Replace the Door latch. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the appropriate Door Lock Driver or Door Unlock Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Doors Fail to Lock and Unlock - Quad Cab RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2093 Right Doors Fail To Lock And Unlock - Quad Cab POSSIBLE CAUSES - DTC present - (P392) Door lock driver right doors wire open - (G778) Door unlock driver right doors wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2094 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (G778) Door Unlock Driver Right Doors circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P392) Door Lock Driver Right Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Right Doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2095 NO: Go To 3 3. (P392) DOOR LOCK DRIVER RIGHT DOORS WIRE OPEN Disconnect the Passenger Door Latch connector. Measure the resistance of the (P392) Door Lock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P392) Door Lock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G778) DOOR UNLOCK DRIVER RIGHT DOORS WIRE OPEN Measure the resistance of the (G778) Door Unlock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST-VER 1. NO: Repair the (G778) Door Unlock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test RKE Inoperative RKE INOPERATIVE POSSIBLE CAUSES - DTC present Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2096 - Transmitter not programmed - RKE transmitter - Remote keyless entry module Diagnostic Test 1. DTC PRESENT With the DRBIII(R), read DTCs. Attempt to operate the door locks with the RKE transmitter. Q: Does the DRBIII(R) display RKE FOB BATTERY LOW? YES: Refer to symptom RKE FOB BATTERY LOW in this category. NO: Go To 2 2. 9001 TESTER AVAILABLE Q: Do you have access to the Miller Special Tool "9001 RF DETECTOR"? NO: Go To 3 YES: Go To 5 3. TRANSMITTER NOT PROGRAMMED Turn the ignition on. Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarmed Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Try the door locks using the Transmitter. Q: Does the RKE System operate properly? YES: Repair complete. Check with the customer to see if the other transmitters) are operating properly. They may have to be programmed also. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. SUBSTITUTE A KNOWN GOOD TRANSMITTER Secure a known good transmitter. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2097 Lock and Unlock the vehicle using the transmitter. Q: Does the RKE System operate properly? YES: Replace the original transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. TEST TRANSMITTER WITH TESTER Using the 9001 RF Detector, follow the instructions on the back of the tester and test the transmitter several times. Q: Does the signal strength measure "STRONG"? YES: Go To 6. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. PROGRAM RKE TRANSMITTER WITH THE DRBIII(R) Turn the ignition on Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarm Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, then PROGRAM New Fob. Follow the instructions on the screen. Exit PROGRAM RKE. Activate the Door Locks using the RKE Transmitter. NOTE: When repairs are complete, ensure all transmitters used with the vehicle have been programmed. Q: Did the door locks respond properly to the RKE transmitter commands? YES: Repair complete. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Alarm Trips On Its Own ALARM TRIPS ON ITS OWN Diagnostic Test 1. LAST VTSS CAUSE With the DRBIII(R) in Inputs/Outputs, read the Last VTSS Cause state. Q: Were there any causes displayed? YES: Check for a possible intermittent condition with the circuit indicated by the DRBIII(R). Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: The condition that caused this symptom is currently not present. Inspect the related wiring harness for a possible intermittent condition. Look for any chafed, pierced, pinched or partially broken wires. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Cylinder Lock Switch INOP CYLINDER LOCK SWITCH INOP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2098 Cylinder Lock Switch Inop POSSIBLE CAUSES - DTC present - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch MUX circuit open - (G163) Cylinder lock switch MUX wire short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2099 - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Measure the voltage between (G163) Cylinder Lock Switch MUX circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2100 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2101 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Does Not Trip VTSS DRIVER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the DRIVER DOOR AJAR SW status. Open the driver door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom DRIVER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the driver's door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the driver door lock. Attempt to trip the VTSS by opening the drivers door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2102 Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Headlamps Fail to Flash When Alarm Is Tripped HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster 1. CHECK FCM DTCS AND HIGH BEAM HEADLAMP OPERATION Attempt to operate the exterior lamps with the headlamp switch. With the DRBIII(R), read FCM DTCs. Q: Were there any problems found? YES: Refer to symptom list for problems related to Exterior Lighting. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Horn Fails to Sound When Alarm Is Tripped HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to the Ignition, Power, Accessory category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 2 2. HORN CIRCUIT DIAGNOSTICS Q: Does the horn operate from the horn button? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Refer to symptom Horns Inoperative in the Ignition, Power, Accessory category. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Left Rear Door Does Not Trip VTSS (4 Door) LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2103 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Left Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom LEFT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the left rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the left rear door lock. Attempt to trip the VTSS by opening the left rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Does Not Trip VTSS PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the passenger door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom PASSENGER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the passenger door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the passenger door lock. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2104 Attempt to trip the VTSS by opening the passenger door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Does Not Trip VTSS (4 Door) RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Right Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom RIGHT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the right rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the right rear door lock. Attempt to trip the VTSS by opening the right rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2105 NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test VTSS Will Not Arm Properly VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster 1. ATTEMPT TO ENABLE THE VTSS Turn the ignition Off to the lock position. Disconnect the battery negative cable wait 5 seconds then reconnect battery cable. Turn the ignition to the On position for 10 seconds, then back Off to the lock position and remove key. Close all doors. Using the key, lock the vehicle with the Driver Door Cylinder Lock Switch and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Go To 2 NO: Go To 3 2. VTSS NOT ENABLED Unlock the vehicle to disarm the VTSS. Ensure all doors are closed. Using the RKE key fob, lock the vehicle and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Test Complete. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. USE DRB TO COMMUNICATE WITH THE SKIM With the DRBIII(R), attempt to communicate with the SKIM. Q: Does the DRBIII(R) communicate with the SKIM? YES: Go To 4 NO: Refer to communication category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 4. DTC OR VTSS INHIBITORS Ensure the doors are closed. With the DRBIII(R), read the active DTC's and the ajar switch states. Q: Does the DRBIII(R) display any closed switches or related DTC's? YES: Refer to the Symptom List and diagnose the appropriate symptom in the DOOR AJAR or related category. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 5 5. CYLINDER LOCK SWITCH CIRCUIT OPEN Turn the ignition on. With the DRBIII(R), read the Driver Cylinder Lock Switch MUX volts while turning the key in the driver door lock cylinder. Q: Did the MUX voltage change from approximately 5.0 volts to 4.0 for lock and 2.4 for unlock? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2106 YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. INSTRUMENT CLUSTER CYLINDER LOCK SWITCH VOLTAGE LOW Disconnect the Cylinder Lock Switch connector. Measure the voltage between Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 7 NO: Go To 8 7. CYLINDER LOCK SWITCH GROUND OPEN Disconnect the Cylinder Lock Switch connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Ground circuit for an open. Perform VTSS VERIFICATION TEST 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 8. CYLINDER LOCK SWITCH MUX OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2107 Disconnect the Cylinder Lock Switch connector. Disconnect the Instrument Cluster C2 connector. Measure the resistance of the Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform VTSS VERIFICATION TEST - 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Cylinder Lock Switch Mux circuit for an open. Perform VTSS VERIFICATION TEST 1A. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: Customer Interest Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2116 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2117 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: All Technical Service Bulletins Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2123 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2124 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2129 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2130 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2131 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2132 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2133 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2134 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2135 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2136 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2137 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls Programming Generic PCMs > Page 2138 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2143 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2144 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2145 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2151 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2152 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2153 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2154 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2155 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2156 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2157 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2158 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2159 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2160 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2165 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2166 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2167 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2168 Engine Control Module: Locations Right Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2169 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Module-Engine Control C1 Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2172 Module-Engine Control C1 Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2173 Module-Engine Control C1 Part 3 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2174 Module-Engine Control C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2175 Module-Powertrain Control C1 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2176 Module-Powertrain Control C2 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2177 Module-Powertrain Control C3 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2178 Module-Powertrain Control C4 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2181 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2182 Engine Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2183 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2184 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2185 Engine Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2186 Engine Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2187 Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2188 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2189 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2190 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2191 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming Engine Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2194 Engine Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2195 Engine Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2196 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2197 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 2203 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2204 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2205 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2206 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2210 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2237 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2238 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 2244 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2245 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2246 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2247 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 5.7L V-8 engine is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches the coils secondary output terminal directly to a spark plug using a rubber boot seal. Each coil is also equipped with a second output terminal. This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank. A separate primary electrical connector is used for each coil. Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The 5.7L engine will not use a conventional distributor. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Dual-Secondary Output, Ignition Coils - 2 knock Sensors - 8 Secondary Ignition Cables - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2258 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2259 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2260 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2261 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2265 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2266 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2267 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2268 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2269 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2273 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2274 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2275 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2276 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2281 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2282 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2283 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2284 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2285 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 2290 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2291 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2292 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2296 Sensor-Intake Air Temperature (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2297 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2298 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2299 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counter-clockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2303 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2304 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2305 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2306 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2310 Sensor-Map (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2311 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2312 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2313 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counter-clockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2314 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2323 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2324 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2325 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2326 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2332 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2333 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2334 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2335 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2338 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2339 Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2340 Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2341 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (3.7L/5.7L) Sensor-Oxygen-Left Rear (3.7L/5.7L LD) Sensor-Oxygen-Left Rear (5.7L HD) Sensor-Oxygen-Right Front (3.7L/5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2342 Sensor-Oxygen-Right Rear (3.7L/5.7L LD) Sensor-Oxygen-Right Rear (5.7L HD) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2343 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2344 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2345 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2349 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2350 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2351 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 2355 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2364 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2365 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2366 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2367 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 2371 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2376 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2377 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2378 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2379 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2384 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2385 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2386 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2387 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2388 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2393 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2397 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2398 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2399 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2400 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2405 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2406 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2410 Idle Speed: Description and Operation A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2415 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips(5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2416 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2425 5.7L The 5.7L engine (345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2426 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. 1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER) 3 CORRESPONDING SPARK PLUG NUMBER Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2434 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2435 Ignition Cable: Service and Repair REMOVAL Spark plug cables on the 5.7L engine are paired on cylinders 1/6, 2/3, 4/7 and 5/8. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. The cable retention clips must also be securely locked. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. If cable tray removal is necessary, release the 4 tray-to-manifold retention clips. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 2440 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... .................................................... 0.045 in (1.14 mm) Torque Spark Plug Torque ............................................................................................................................... .................................... 13 +/- 2 ft.lbs. (18 +/- 3 Nm) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2441 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2442 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2443 Spark Plug: Testing and Inspection The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2444 Spark Plug: Service and Repair REMOVAL Eight of the 16 spark plugs are located under an ignition coil; the other 8 are not. If spark plug being removed is under coil, coil must be removed to gain access to spark plug. Refer to Ignition Coil Removal/Installation and observe all CAUTIONS and WARNINGS. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil (if coil removal is necessary), spray compressed air around coil base at cylinder head cover. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 5. Inspect spark plug condition. INSTALLATION 1. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into cylinder head by hand to avoid cross threading aluminum threads. To aid in installation, attach a piece of rubber hose, or an old spark plug boot to spark plug. 3. The 5.7L V-8 is equipped with torque critical design spark plugs. Do not exceed 15 ft.lbs. torque. Tighten spark plugs. Refer to torque specifications. 4. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 5. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. 6. Install ignition coil(s) to necessary spark plugs. 7. Install spark plug cables to remaining spark plugs. Remember to apply dielectric grease to inside of boots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All gauge pressure indications should be equal, with no more than 25% leakage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2448 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 7. Refer to - ENGINE SPECIFICATIONS) for the correct engine compression pressures. See: Engine, Cooling and Exhaust/Engine/Specifications/Mechanical Specifications/Service Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2454 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2455 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2456 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2457 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2461 Sensor-Intake Air Temperature (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2462 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2463 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2464 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counter-clockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2468 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2469 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2470 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2471 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2472 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation Body Control Module: Description and Operation The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2478 Body Control Module: Symptom Related Diagnostic Procedures Air Bag System AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems Diagnostic Test 1. AIRBAG WARNING INDICATOR ON WITHOUT ACTIVE TROUBLE CODES NOTE: Ensure the battery is fully charged. Turn the ignition on. Make sure that all active DTC's have been repaired before performing this procedure. With the DRBIII(R) read the WARNING LAMP STATES. Q: With no active DTCs, Does the LAMP REQ by ACM monitor show ON? YES: Go To 2 NO: Perform ORC VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test 2. REPLACE THE ORC WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER (ORC) IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. NOTE: When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected. Repair Replace the ORC. Perform ORC VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test NOTE: When reconnecting Airbag system components, the ignition must be turned off and the battery must be disconnected. Audio System Audio System Diagnosis Table Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2479 Audio System Diagnosis Table Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2480 Audio System Diagnosis Table Part 3 Of 3 Any diagnosis of the Audio system should begin with the use of a scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Chime Inoperative CHIME INOPERATIVE POSSIBLE CAUSES - Cluster Diagnostic Test 1. ACTUATE THE CHIME WITH THE DRBIII Turn the ignition on. Close the doors. With the DRBIII(R) select: Electro/Mech Cluster and actuate the Chime. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2481 Q: Does the chime sound when actuated by the DRBIII(R)? YES: If the chime operates as it should, check for other reasons that the chime is being inoperative. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Sounds With Drivers Door Open and Key Removed From Ignition CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2482 Chime Sounds With Driver Door Open Key Removed POSSIBLE CAUSES - Key-in IGN SW status - Ignition switch shorted - (G26) Key-in ignition sw sense short to ground - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2483 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: Ensure the exterior lamps turn on and off properly and are off before continuing this test. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Remove the key from the ignition switch. Q: Does the DRBIII(R) show Key-In IGN OPEN? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. KEY-IN IGN SWITCH SHORTED Disconnect the Ignition Switch connector. Q: Did the chime turn off? YES: Check the Ignition Lock Cylinder for damage. If OK replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2484 3. (G26) KEY-IN IGNITION SWITCH SENSE WIRE SHORT TO GROUND Turn ignition off. Disconnect the Ignition Switch connector. Disconnect the Cluster C3 connector. Measure the resistance of the (G26) Key-in Ignition Switch Sense circuit to ground at the Ignition Switch connector. Q: Is the resistance below 100.0 ohms? YES: Repair the (G26) Key-In Ignition Switch Sense wire for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Warning System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2485 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2486 WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired chime warning system inputs to the ElectroMechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and methods. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Programmable Communications Interface (PCI) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Key In Ignition and Drivers Door Open Chime Inoperative KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2487 Key In Ignition And Driver's Door Open Chime Inoperative POSSIBLE CAUSES - (Z42) Ground open - (G26) Key-in ignition switch open - Ignition switch - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2488 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: The driver's door ajar switch must be operational for the result of this test to be valid. Ensure that the Key is still in the Ignition Switch. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Q: Does the DRBIII(R) show Key-In IGN CLOSED? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. IGNITION SWITCH GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch connector. Turn all lights off. Measure the resistance between ground and the (Z42) Ground circuit in the ignition switch harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2489 NO: Repair the (Z42) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. IGNITION SWITCH OPEN Connect the ignition switch connector if disconnected. Turn ignition on. With the ignition switch connector connected, back jumper the (G26) Key-In Ignition Switch Sense circuit to ground at the ignition switch connector. With the DRBIII(R), enter Instrument Cluster Input/Outputs and observe the Key-In IGN SW status. Q: Does the DRBIII display Key-In IGN SW: Closed? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. KEY-IN IGNITION SWITCH SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch harness connector. Disconnect the Cluster C3 harness connector. Measure the resistance of the (G26) Key-In Ignition Switch Sense circuit between the ignition switch connector and the Instrument Cluster C3 connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2490 Q: Is the resistance below 5.0 ohms? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G26) Key-In Ignition Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Vehicle Speed Warning Chime Problem VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in cluster - Cluster Diagnostic Test 1. WITH THE DRBIII CHECK THE COUNTRY CODE SETTING NOTE: The high speed warning chime is for Gulf Coast Countries only. Turn the ignition on. With the DRBIII(R) in Miscellaneous check the Cluster country code setting. Q: Is the country code incorrect? YES: Program the correct country code. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Heater Control Illumination Inoperative A/C HEATER CONTROL ILLUMINATION INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2491 A/C Heater Control Illumination Inoperative POSSIBLE CAUSES - Faults present in the cluster (MIC) - (E16) Panel lamps driver circuit open - Bulb(s) - filament open (single-zone HVAC module only) - Cluster (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2492 - A/C Heater control Diagnostic Test 1. CHECK FOR DTCs IN THE CLUSTER (MIC) Turn the ignition on. With the DRBIII(R), read Cluster DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. TEST (E16) PANEL LAMPS DRIVER CIRCUIT USING A TEST LIGHT Turn the Headlamp switch on. Rotate the Cargo Dome switch to the full brightness setting. CAUTION: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (E16) Panel Lamps Driver circuit in the A/C Heater Control C1 harness connector. Q: Does the test light illuminate brightly? YES: (Dual-Zone Systems) Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: (Single-Zone Systems) Go To 3 NO: Go To 4 3. INSPECT THE INOPERATIVE BULB(S) Turn the ignition off. Remove the inoperative bulb(s) from the A/C Heater Control. NOTE: If necessary, hold the bulb in front of a lamp to see the filament. Inspect the bulb(s). Q: Is each inoperative bulb Ok? YES: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the inoperative bulb(s). Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2493 Tests and Associated Procedures/Verification Tests/Body Verification Test 4. CHECK (E16) PANEL LAMPS DRIVER CIRCUIT FOR AN OPEN Disconnect the A/C Heater Control C1 harness connector. Disconnect the Cluster C1 harness connector. Measure the resistance of the (E16) Panel Lamps Driver circuit between the A/C Heater Control C1 harness connector and the Cluster C1 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (E16) Panel Lamps Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Flashing A/C STATUS INDICATOR FLASHING Theory of Operation Running the AC Cooldown test will cause the A/C status indicator to flash. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. When the A/C status indicator is flashing, it will not indicate A/C operating status. However, the A/C mode switch will continue to function normally. For vehicles equipped with EBL, when the A/C status indicator is flashing, the EBL status indicator will not function. However, the EBL mode switch will continue to function normally. POSSIBLE CAUSES - A/C Cooldown test failed 1. PERFORM THE A/C COOLDOWN TEST NOTE: The following are prerequisites of the Cooldown Test. Verify each of the following before running the test: - Verify that no Evaporator Temperature Sensor related DTCs are not active. If active, diagnose and repair the DTC before proceeding. - Verify that the refrigerant system has an adequate charge. Check and repair as necessary before proceeding. - Verify that the blower motor operates correctly in all speeds. Diagnose and repair all blower related faults before proceeding. - Verify that the work area ambient temperature is above 21.1° C (70° F) before proceeding. Move the vehicle to a warmer work area if necessary. - Verify that the evaporator temperature is above 12.7° C (55° F) before proceeding. - Verify that the Mode Select control is set to the panel position. - Verify that the A/C compressor is not running. If the compressor is running, turn the A/C off and allow the evaporator to warm up before proceeding. Start the engine. Turn the Blower control to the high speed position. With the DRBIII(R) in HVAC, select System Tests and then select AC Cooldown test. Allow one minute for the test to complete. One or more Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2494 status messages will display on the DRBIII(R) after running the AC Cooldown Test. These messages will clear after paging back out of this test function. Therefore, it is important to note all messages before doing so. Q: Does the DRBIII(R) display a status message that indicates a fault has occurred? Yes, Blower Not On High Diagnose and repair the fault. Refer to Blower Not On High for the diagnostic test procedure. Yes, Cooldown Test Sensor Failure Diagnose and repair the fault. Refer to Cooldown Test Sensor Failure for the diagnostic test procedure. Yes, Cooldown Time Excessive Fault Diagnose and repair the fault. Refer to Cooldown Time Excessive Fault for the diagnostic test procedure. Yes, Cooldown Test Too Cold To Start Diagnose and repair the fault. Refer to Cooldown Test Too Cold To Start for the diagnostic test procedure. NO: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW A/C STATUS INDICATOR WILL NOT ILLUMINATE - A/C HEATER CONTROL WITHOUT EBL SW Theory of Operation Failing recalibration will prevent the A/C status indicator from operating but still allows the A/C mode switch to function normally. This test verifies if the status indicator is inoperable due to either a recalibration failure or a fault with the status indicator. POSSIBLE CAUSES - HVAC door recalibration failed - A/C Heater control Diagnostic Test 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Failed? YES: Diagnose and repair the fault(s). NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Dual-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2495 Actuator Circuit Test Diagnostics (Dual-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2496 messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test fault message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2497 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2498 Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2499 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2500 VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2501 VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C29) Mode Door 2 Driver circuit and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C33) Passenger Blend Door Driver circuit for a short to the (C29) Mode Door 2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 12 12. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2502 Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 13 NO: Go To 14 13. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 14. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Single-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2503 Actuator Circuit Test Diagnostics (Single-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2504 shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2505 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2506 Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2507 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2508 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C29) Mode Door 2 Driver circuit for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2509 11. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 12 NO: Go To 13 12. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2510 VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 13. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Dual-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2511 Blend/Mode/Recirc Door Operation Improper (Dual-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2512 - Door(s) bound up, warped, worn, damaged - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Passenger Blend Door Function Test Go To 6 Driver Blend Door Function Test Go To 7 Recirculation Door Function Test Go To 8 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2513 Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK PASSENGER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Passenger Blend control to the full hot position. Move the Passenger Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the passenger's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Passenger Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK DRIVER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Driver Blend control to the full hot position. Move the Driver Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the driver's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Driver Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Single-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2514 Blend/Mode/Recirc Door Operation Improper (Single-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open - Door(s) bound up, warped, worn, damaged Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2515 - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Blend Door Function Test Go To 6 Recirculation Door Function Test Go To 7 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2516 YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Blend control to the full hot position. Move the Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Motor Inoperative (Except SRT10) BLOWER MOTOR INOPERATIVE (EXCEPT SRT10) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2517 Blower Motor Inoperative (Except SRT10) POSSIBLE CAUSES - (C7) Blower motor feed circuit shorted to ground - (A970) Fused B(+) circuit shorted to ground - (C70) Blower motor high driver circuit open - (Z134) Ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2518 - (C7) Blower motor feed circuit open - (A970) Fused B(+) circuit open - IPM fuse #4 open - Blower motor - Ignition switch - A/C heater control Diagnostic Test 1. CHECK THE FUSE Turn the ignition off. Remove and inspect IPM Fuse #4. Q: Is the fuse open? YES: Replace IPM Fuse #4 and Go To 2. NO: Reinstall IPM Fuse #4 and Go To 5. 2. CHECK BLOWER MOTOR OPERATION Turn the ignition on. Turn the blower on and operate it in all speeds and modes. Q: Does the blower motor operate properly without blowing the fuse? YES: Check the (C7) Blower Motor Feed circuit and the (A970) Fused B(+) circuit for an intermittent short to ground. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2519 Turn the ignition off. Disconnect the Blower Motor harness connector. Measure the resistance of the (C7) Blower Motor Feed circuit between ground and the Blower Motor harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C7) Blower Motor Feed circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (A970) FUSED B(+) CIRCUIT FOR A SHORT TO GROUND Disconnect the Ignition Switch harness connector. Measure the resistance of the (A970) Fused B(+) circuit between ground and the Ignition Switch harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (A970) Fused B(+) circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor and fuse. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2520 Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Blower Motor harness connector. Q: Does the test light illuminate brightly? YES: Go To 6 NO: Go To 9 6. CHECK BLOWER MOTOR OPERATION BY BYPASSING THE A/C HEATER CONTROL Turn the ignition off. Connect a jumper wire between ground and the (C70) Blower Motor High Driver circuit in the Blower Motor harness connector. Turn the ignition on. Q: Does the blower motor run at high speed? YES: Go To 7 NO: Replace the Blower Motor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2521 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor harness connector. Measure the resistance of the (C70) Blower Motor High Driver circuit between the A/C Heater Control C2 harness connector and the Blower Motor harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 8 NO: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (Z134) GROUND CIRCUIT FOR AN OPEN Measure the resistance of the (Z134) Ground circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the A/C Heater Control. NO: Repair the (Z134) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2522 NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Repair the (C7) Blower Motor Feed circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (A970) FUSED B(+) CIRCUIT FOR AN OPEN NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (A970) Fused B(+) circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (A970) Fused B(+) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Speed Does Not Correspond With Control Setting Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2523 BLOWER SPEED DOES NOT CORRESPOND WITH CONTROL SETTING Blower Speed Does Not Correspond With Control Setting POSSIBLE CAUSES - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2524 - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to voltage - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted together - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit open - Blower motor resistor block open - A/C heater control Diagnostic Test 1. CHECK IF THE BLOWER MOTOR RUNS WITH THE BLOWER CONTROL IN THE OFF POSITION Turn the Blower control to the Off position. Turn the ignition on. Q: Does the blower motor run? YES: Go To 2 NO: Go To 3 2. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms on any of the circuits? YES: Repair all circuits with a resistance below 10K ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2525 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Does the test light illuminate brightly on each circuit? YES: Go To 4 NO: Go To 8 4. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the voltage of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is there voltage present on any of the circuits? YES: Repair all circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: GO TO 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2526 5. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR A SHORT TO THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C71) Blower Motor Low Driver circuit and the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C71) Blower Motor Low Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C71) Blower Motor Low Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR A SHORT TO THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C73) Blower Motor M2 Driver circuit and the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C73) Blower Motor M2 Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C73) Blower Motor M2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR A SHORT TO THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2527 Measure the resistance between the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C72) Blower Motor M1 Driver circuit for a short to the (C70) Blower Motor High Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 9 NO: Repair the (C71) Blower Motor Low Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2528 Measure the resistance of the (C73) Blower Motor M2 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 10 NO: Repair the (C73) Blower Motor M2 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR AN OPEN Measure the resistance of the (C72) Blower Motor M1 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 11 NO: Repair the (C72) Blower Motor M1 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 11. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2529 Measure the resistance of the (C70) Blower Motor High Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor Resistor Block. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test EBL Status Indicator Flashing EBL STATUS INDICATOR FLASHING Theory of Operation Running the HVAC Door Recalibration will cause the EBL status indicator to flash. If recalibration fails, the status indicator will continue to flash until either the system passes recalibration or the ignition key is cycled. When the EBL status indicator is flashing, it will not indicate EBL operating status. However, the EBL mode switch will continue to function normally. When the EBL status indicator is flashing, the A/C status indicator will not function. However, the A/C mode switch will continue to function normally. POSSIBLE CAUSES - HVAC door recalibration failed 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Passed? YES: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Diagnose and repair the fault(s). Horn HORNS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2530 Horns Inoperative POSSIBLE CAUSES - DTC present - Fuse #45 - Horns - Horn ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2531 - Horn relay output circuit open - Horn switch - Horn switch ground - Clockspring - Horn switch sense open - Integrated power module - Instrument cluster - Front control module Diagnostic Test 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to symptom list. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. ACTUATE HORN RELAY With the DRBIII(R), actuate the Horn Relay. Q: Do the horns operate? YES: Go To 3 NO: Go To 7 3. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch. Measure the resistance of the Horn Switch ground circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the horn switch ground as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch connector. WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the Horn switch connector and ground. Q: Did the horns sound? YES: Replace the horn switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CLOCKSPRING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2532 Turn the ignition off. Disconnect the clockspring C1 connector. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the clockspring connector and ground. Q: Did the horns sound? YES: Replace the clockspring. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. HORN SWITCH SENSE Turn the ignition off. Disconnect the clockspring C1 connector. Disconnect the Instrument Cluster C3 connector. NOTE: Check connectors - Clean/repair as necessary. Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Instrument Cluster C3 connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Horn Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2533 7. CHECK FUSE #45 Turn the ignition off. Using a 12-volt test light connected to ground, check the Horn fuse #45 in the IPM. Q: Is the fuse open? YES: Replace the fuse. Check for a short to ground in the Horn Relay Output circuit from the IPM to the horns. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. HORN RELAY OUTPUT Disconnect a horn connector. With the DRBIII(R), actuate the Horn Relay. Using a 12-volt test light connected to ground, check the Horn Relay Output circuit. Q: Does the test light illuminate brightly? YES: Go To 9 NO: Go To 10 9. HORN GROUND CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2534 Turn the ignition off. Disconnect the Horn connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit in the horn connector. Q: Does the test light illuminate brightly? YES: Replace the Horns. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Ground circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. HORN RELAY OUTPUT CIRCUIT OPEN Gain access to the IPM C1 connector. Using a 12-volt test light connected to ground, back probe the Horn Relay Output circuit in the IPM C1 connector. Turn the ignition on. With the DRBIII(R), the actuate the horn relay. Q: Does the test light illuminate brightly? YES: Repair the Horn Relay Output circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2535 11. INTEGRATED POWER MODULE Turn the ignition off. Remove the Front Control Module from the Integrated Power Module. NOTE: - Check connectors - Clean/repair as necessary. - The test light is still connected to the C1 connector. Momentarily jumper the Horn Relay Control circuit to ground at the FCM connector. Q: Does the test light illuminate brightly? YES: Replace the Front Control Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Integrated Power Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test All Gauges Inoperative ALL GAUGES INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2536 All Gauges Inoperative POSSIBLE CAUSES - No response - PCI BUS - No response - PCI BUS - powertrain control module - PCI BUS - instrument cluster - (F21) Fused ignition switch output (run/start) circuit short to ground - (F1) Fused ignition switch output (off/run/start) circuit short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2537 - (F21) Fused ignition switch output (run/start) circuit open - (F1) Fused ignition switch output (off/run/start) circuit open - (Z18) Instrument cluster ground circuit for an open - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS NOTE: Diagnose and repair any MIC, PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test. Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), select Body, MIC, SYSTEM TESTS, PCM Monitor. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PCI BUS - INSTRUMENT CLUSTER Turn the ignition on. With the DRBIII(R), select Body, MIC, MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Inspect the #20 Fuse in the PDC. If the fuse is open, replace with proper rated fuse. Turn the ignition on for one minute. Turn the ignition off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2538 Inspect the #20 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F21) Fused Ignition Switch Output (Unlock/Run) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. If the fuse is open, replace with the proper rated fuse. Turn the ignition on for 1 minute. Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F1) Fused Ignition Switch Output (Run/Start) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2539 Q: Is the voltage below 10.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F1) Fused Ignition Switch Output (Off/Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F1) Fused Ignition Switch Output (Off/Run/ Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (Z18) Instrument Cluster Ground circuit. Q: Is the resistance below 5.0 ohms? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2540 NO: Repair the (Z18) Instrument Cluster Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Any PCI Indicator Inoperative ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - Indicator message not received - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - INSTRUMENT CLUSTER With the DRBIII(R), select MIC, then MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE INSTRUMENT CLUSTER. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. NO RESPONSE - PCI BUS With the DRBIII(R), select Body, MIC, MONITORS, PCI BUS MONITORS. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE POWERTRAIN CONTROL MODULE. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. INDICATOR MESSAGE NOT RECEIVED NOTE: Diagnose and repair any PCM or BCM DTCs before proceeding with this test. Perform the Instrument Cluster Self Test. Depress and hold the Trip Odometer button while turning the ignition from the off to the on position. Observe the indicator in question. Q: Did the indicator illuminate? YES: Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Always On BRAKE WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2541 Brake Warning Indicator Always On POSSIBLE CAUSES - (B20) Brake fluid level sensor sense circuit short to ground - (B25) Park brake switch sense circuit short to ground - Brake fluid level sensor - Park brake switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2542 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. BRAKE FLUID LEVEL SENSOR NOTE: Diagnose and repair any MIC, Brake, or Communication DTCs before proceeding with this test. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance of the Brake Fluid Level Sensor between pin 1 and pin 2. Q: Does the resistance measure less than 900 ohms? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance between ground and the (B20) Brake Fluid Level Sensor Sense circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2543 Q: Is the resistance below 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PARK BRAKE SWITCH Turn the ignition off. Disconnect the Park Brake Switch harness connector. Turn the ignition on. Observe the Brake warning indicator. Q: Did the Brake warning indicator illuminate briefly and then turn off? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. (B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Park Brake Switch harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2544 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (B25) Park Brake Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. ANTI-LOCK BRAKES MODULE Turn the ignition off. Reconnect any harness connector(s) that were previously disconnected. Turn the ignition on. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Inoperative BRAKE WARNING INDICATOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2545 Brake Warning Indicator Inoperative POSSIBLE CAUSES - (Z420) Brake fluid level sensor ground circuit open - (B25) Park brake switch sense circuit open - (B20) Brake fluid level sense circuit open - Park brake switch - Brake fluid level sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2546 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. FAULT LOCATION NOTE: Diagnose and repair any MIC, ABS, or Communication DTCs before proceeding with this test. Q: Is the Brake warning indicator only inoperative using the Park Brake? YES: Go To 2 NO: Go To 4 2. PARK BRAKE SWITCH Disconnect the Park Brake Switch harness connector. Connect a jumper wire between the (B25) Park Brake Switch Sense circuit and ground. Turn the ignition on. Observe the BRAKE indicator. Q: Did the BRAKE indicator illuminate? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2547 Turn the ignition off. Disconnect the (B25) Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (B25) Park Brake Switch Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. BRAKE FLUID LEVEL SENSOR Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Q: Does the Brake warning indicator illuminate? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2548 5. (Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance between ground and the (Z420) Brake Fluid Level Sensor Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z420) Brake Fluid Level Sensor Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. (B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance of the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2549 NO: Go To 7 7. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Anti-lock Brakes Module harness connector. Connect a jumper wire between the (B25) Brake Fluid Level Sensor Sense circuit and ground. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Fuel Gauge Inaccurate FUEL GAUGE INACCURATE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2550 Fuel Gauge Inaccurate POSSIBLE CAUSES - Fuel level sensor wiring - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2551 1. DTC PRESENT NOTE: Diagnose and repair any PCI Bus problems before proceeding with this test. Turn the ignition on. With the DRBIII(R), read the PCM DTCs. Q: Does the DRBIII(R) display any Fuel Level Sensor related DTC? YES: Refer to the Powertrain Diagnostic Information for the related symptom(s). Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test as follows: Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the Fuel Gauge during the Self Test. The Fuel Gauge pointer should pause at each of these following positions: E, 1/4, 1/2, 3/4, Full, and back to E. Q: Does the Fuel Gauge function as described above? YES: Go To 3 NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. FUEL LEVEL SENSOR WIRING Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Disconnect the PCM C2 and C3 harness connectors. Measure the resistance of the (N4) Fuel Level Sensor Signal circuit between the Fuel Pump Module harness connector and the PCM harness connector. Measure the resistance of the (K900) Sensor Ground circuit between the Fuel Pump Module harness connector and the PCM harness connector. Q: Is the resistance below 5.0 ohms on both circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2552 YES: Replace the Fuel Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the circuits with a resistance above 5.0 ohms for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Gauge Inoperative - Gas Engines ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module - Instrument cluster DIAGNOSTIC TEST 1. POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any PCM DTCs? YES: Refer to the DRIVEABILITY category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Perform the Instrument Cluster Self Test. NOTE: The Self Test can be initiated manually by depressing and holding the Trip Reset button while turning the ignition on, or by using the DRBIII(R). Observe the gauge in question while the Instrument Cluster performs the Self Test. The gauges should position at the following calibrations points: Speedometer MPH: 0, 20, 60, 90 Tachometer Gas: 0, 1000, 3000, 6000 Fuel: E, 1/4, 1/2, 3/4, F Coolant: Cold, 1/4, 1/2, 3/4, HI Volts: 6, 9, 12, 15, 17 Q: Did the gauge in question operate properly? YES: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wire harness. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test PRNDL Not Displaying Correct Position (EATX Vehicles) PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster DIAGNOSTIC TEST 1. DTC PRESENT NOTE: - Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle. - Ensure that there is communication between the Cluster and PCM before proceeding with this test. - Diagnose and repair any DTCs before proceeding with this test. - Ensure that the PCM passes the Shift Lever Test with the DRBIII(R) before proceeding with this test. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2553 Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any MIC or PCM DTCs? YES: Refer to the correct symptom list for problems related to DTCs. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test. Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the PRNDL display during the Self Test. Q: Did any part of the VF display fail to illuminate? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wiring harness, refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off SEAT BELT WARNING INDICATOR ALWAYS OFF Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2554 Seat Belt Warning Indicator Always Off POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster Diagnostic Art Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2555 1. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2556 Seat Belt Warning Indicator Always Off - Standard Cab POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2557 1. (G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on SEAT BELT WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2558 Seat Belt Warning Indicator Always On POSSIBLE CAUSES - (Z951) Seat belt switch ground circuit for an open - (G10) Seat belt switch sense circuit open - Seat belt switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2559 DIAGNOSTIC TEST 1. CHECK THE OPERATION OF THE SEAT BELT SWITCH Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate for approximately 4 seconds and then turn off? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Measure the resistance between ground and the (Z951) Seat Belt Switch Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2560 Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2561 Seat Belt Warning Indicator Always On - Standard Cab POSSIBLE CAUSES - (F983) Fused ignition switch output (run-acc) circuit open - (Z951) Seat belt switch ground circuit open - (G10) Seat belt switch sense circuit open - Seat belt tensioner reducer Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2562 - Seat belt switch - Instrument cluster 1. (F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN Turn the ignition off. Disconnect the Seat Belt Tensioner Reducer harness connector. Turn the ignition on. Measure the voltage between the (F983) Fused Ignition Switch Output (Run-Acc) circuit and ground in the Tensioner Reducer harness connector. Q: Is the voltage above 10.5 volts? YES: Go To 2 NO: Repair the (F983) Fused Ignition Switch Output (Run-Acc) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. SEAT BELT TENSIONER REDUCER Ensure that the Seat Belt Tensioner Reducer harness connector is connected. Measure the voltage between the (G10) Seat Belt Switch Sense circuit and ground in the Seat Belt Tensioner Reducer harness connector (cavity 2). Q: Is there any voltage present? YES: Go To 3 NO: Replace the Seat Belt Tensioner Reducer. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. SEAT BELT SWITCH Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2563 Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Measure the resistance between ground and the (Z951) Seat Belt Switch circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2564 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Open DRIVER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2565 Driver Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z75) driver door ajar switch ground circuit - Open (G75) driver door ajar switch sense circuit - Open driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2566 DIAGNOSTIC TEST 1. OPEN DRIVER DOOR AJAR SWITCH Disconnect the Driver Door Latch connector. Connect a jumper wire between the (G75) Sense circuit and the (Z75) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z75) DRIVER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z75) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES:Go To 3 NO: Repair the (Z75) Driver Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2567 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G75) Driver Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G75) Driver Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Shorted to Ground DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2568 Driver Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G75) Driver door ajar switch sense circuit short to ground - Driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2569 DIAGNOSTIC TEST 1. DRIVER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Driver Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G75) Driver Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G75) Driver Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Open LEFT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2570 Left Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z79) left rear door ajar switch ground circuit - Open (G77) left rear door ajar switch sense circuit - Open left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2571 DIAGNOSTIC TEST 1. OPEN LEFT REAR DOOR AJAR SWITCH Disconnect the Left Rear Door Latch connector. Connect a jumper wire between the (G77) Sense circuit and the Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO:Go To 2 2. OPEN (Z79) LEFT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z79) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z79) Left Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2572 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G77) Left Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Shorted to Ground LEFT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2573 Left Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G77) Left rear door ajar switch sense circuit short to ground - Left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2574 DIAGNOSTIC TEST 1. LEFT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Left Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G77) Left Rear Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Open PASSENGER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2575 Passenger Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z74) passenger door ajar switch ground circuit - Open (G74) passenger door ajar switch sense circuit - Open passenger door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2576 DIAGNOSTIC TEST 1. OPEN PASSENGER DOOR AJAR SWITCH Disconnect the Passenger Door Latch connector. Connect a jumper wire between the (G74) Sense circuit and the (Z74) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z74) PASSENGER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z74) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z74) Passenger Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2577 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G74) Passenger Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G74) Passenger Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Shorted to Ground PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2578 Passenger Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G74) Passenger door ajar switch sense circuit short to ground - Passenger door ajar switch - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2579 1. PASSENGER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Passenger Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G74) Passenger Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G74) Passenger Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Open RIGHT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2580 Right Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z72) right rear door ajar switch ground circuit - Open (G76) right rear door ajar switch sense circuit - Open right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2581 DIAGNOSTIC TEST 1. OPEN RIGHT REAR DOOR AJAR SWITCH Disconnect the Right Rear Door Latch connector. Connect a jumper wire between the (G76) Sense circuit and the (Z72) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Right Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z72) RIGHT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z72) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z72) Right Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2582 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G76) Right Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Shorted to Ground RIGHT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2583 Right Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G76) Right rear door ajar switch sense circuit short to ground - Right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2584 DIAGNOSTIC TEST 1. RIGHT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Right Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Right Rear Door Ajar Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G76) Right Rear Door Ajar Switch Sense circuit and test for a short to ground. Q: Does the test light illuminate brightly? YES: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Average Fuel Economy Inaccurate or Wrong AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2585 - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. CMTC or EVIC Inoperative CMTC OR EVIC INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2586 CMTC Or EVIC Inoperative POSSIBLE CAUSES - (F21) Fused ignition switch output (run/start) circuit open - (Z13) Electronic overhead module ground circuit open - Electronic overhead module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2587 1. (F21) FUSED IGNITION RUN/START CIRCUIT OPEN NOTE: Diagnose and repair any MIC, FCM, PCM, or Communication DTCs before proceeding. Turn the ignition off. Disconnect the Electronic Overhead Module harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 0.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (Z13) ELECTRONIC OVERHEAD MODULE GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance between ground and the (Z13) Electronic Overhead Module Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z13) Electronic Overhead Module Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Compass Test Failure COMPASS TEST FAILURE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2588 WHEN MONITORED With the ignition on. SET CONDITION The Electronic Overhead Module (EOM) display reads "FAILED SELF TEST." POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Depress and hold the RESET and C/T buttons while turning the ignition on. NOTE: This test may also be performed using the DRBIII(R). Q: Does the EOM or DRBIII(R) display "FAILED SELF TEST"? YES: Replace the EOM. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Distance to Empty Inaccurate or Wrong DISTANCE TO EMPTY INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Elapsed Ignition On Time Inaccurate or Wrong ELAPSED IGNITION ON TIME INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2589 Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Temperature Display Inaccurate or Inoperative TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Electronic overhead module 1. AMBIENT TEMPERATURE SENSOR NOTE: - Diagnose and repair any FCM, EOM, PCM, or Communication DTCs before proceeding with this test. - The Ambient Temperature Sensor is hardwired to the FCM (Diesel), or to the PCM. Ambient temperature information is transmitted to the EOM via the PCI Bus. Turn the ignition off. Disconnect the Ambient Temperature Sensor harness connector. Measure the resistance of the Ambient Temperature Sensor using the following temperature/resistance values: 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.88 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms 50° C (122° F) Sensor Resistance = 3.33 - 3.88 Kilohms Q: Is the Ambient Temperature Sensor resistance measurement within the min/max specifications? YES: Go To 2 NO: Replace the Ambient Temperature Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. ELECTRONIC OVERHEAD MODULE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2590 Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Press and hold the C/T and Reset buttons. Turn the ignition on. NOTE: NOTE: The self test can also be performed using the DRBIII(R). Observe the EOM display at the conclusion of the self test. Q: Does the EOM display "Passed Self Test"? YES: Test Complete. NO: Replace and configure the EOM. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Trip Odometer Inaccurate or Wrong TRIP ODOMETER INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC VEHICLE INFORMATION CENTER NOTE: - Diagnose and repair any FIDEM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the OEM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. All Door Locks Inoperative ALL DOOR LOCKS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2591 All Door Locks Inoperative POSSIBLE CAUSES - DTC present - Fuse #22 open - (A941) Fuse B+ circuit open - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2592 Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock or Cluster related DTC's? YES: Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. FUSE #22 OPEN Test both sides of fuse #22 in the PDC. Q: Is there 12 volts on both sides of fuse #22? YES: Go To 3 NO: Replace the fuse if open and retry the system. If the fuse blows, locate and repair a short to the Instrument Cluster. The 12 volt supply to the fuse is a bus bar in the PDC. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. (A941) FUSED B+ CIRCUIT OPEN Turn the ignition off. Remove the instrument cluster. Measure the voltage between the (A941) Fused B+ circuit and ground (cavity 2 in the C1 connector to ground). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2593 Q: Is the voltage above 10.0 volts on the Fused B+ circuit? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Fused B+ circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Automatic (Rolling) Door Locks Inoperative AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Door ajar switch status incorrect - TPS or VSS DTC's - Auto door locks not enabled - Instrument cluster Diagnostic Test 1. CHECK THE DOOR AJAR SWITCH STATUS Ensure all doors are closed. With the DRBIII, enter "Electro/Mech Cluster" then "Input/Output" and observe all of the Door Ajar states. Q: Does the DRBIII display CLOSED for any door ajar state? YES: Select the appropriate Door Ajar Circuit Shorted: NO: Go To 2 2. ANY TPS OR VSS RELATED DTC'S With the DRBIII read "Engine" and "Anti-Lock Brakes" DTC's. Q: Does the DRBIII display any Throttle Position Sensor or Vehicle Speed Sensor related DTC's? YES: Diagnose and repair the DTC's. NO: Go To 3 3. ENABLE AUTO DOOR LOCKS With the DRBIII, enter "Electron/Mech Cluster" then "Miscellaneous" and observe the rolling door lock status. Q: Does the DRBIII display ROLLING DOOR LOCKS: ENABLED YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: With the DRBIII, enable the Auto Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2594 Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Cylinder Lock Switch Inoperative CYLINDER LOCK SWITCH INOPERATIVE Cylinder Lock Switch Inoperative POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2595 DTC PRESENT - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch mux circuit open - (G163) Cylinder lock switch mux wire short to ground - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Turn the ignition on. Measure the voltage between (G163) Cylinder Lock Switch Mux circuit and ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2596 Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2597 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Door Lock Inhibit Inoperative DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster Diagnostic Test 1. CHIME INOPERATIVE Turn the ignition off but leave the key in the ignition. Open the drivers door. Q: Does the chime sound? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Perform the test "KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE". See: Chime System/Key In Ignition and Drivers Door Open Chime Inoperative Driver Door Fails to Lock and Unlock DRIVER DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2598 Driver Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P1) Door unlock driver left front wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2599 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P1) Door Unlock Driver Left Front circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Driver Door lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2600 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Driver Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P1) DOOR UNLOCK DRIVER LEFT FRONT WIRE OPEN Measure the resistance of the (P1) Door Unlock Driver Left Front circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P1) Door Unlock Driver Left Front wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Fails to Lock & Unlock LEFT REAR DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2601 Left Rear Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P5) Door unlock driver left rear wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2602 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks to diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P5) Door Unlock Driver Left Rear circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the left doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2603 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Left Rear Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P5) DOOR UNLOCK DRIVER LEFT REAR WIRE OPEN Measure the resistance of the (P5) Door Unlock Driver Left Rear circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P5) Door Unlock Driver Left Rear wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Door Lock Motor Inoperative ONE DOOR LOCK MOTOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2604 POSSIBLE CAUSES - DTC's present - Door lock driver or door unlock driver circuit open - Door latch Diagnostic Test 1. CHECK DOOR LOCK MOTOR CIRCUIT With the DRBIII(R), read DTCs. If there are any door lock related DTC's, refer to symptom list for problems related to Power Door Locks and diagnose and repair the DTC's. Disconnect the inoperative Door Latch connector. Connect a 12 volt test light between the Door Lock Driver and the Door Unlock Driver circuits in the latch connector. NOTE: Graphic shows Passenger Latch - all others similar. Operate the door locks several time in the lock and unlock positions from a door lock switch and observe the test light. Q: Does the test light illuminate brightly when the locks are actuated in both directions? YES: Replace the Door latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the appropriate Door Lock Driver or Door Unlock Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Doors Fail to Lock and Unlock - Quad Cab RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2605 Right Doors Fail To Lock And Unlock - Quad Cab POSSIBLE CAUSES - DTC present - (P392) Door lock driver right doors wire open - (G778) Door unlock driver right doors wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2606 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (G778) Door Unlock Driver Right Doors circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P392) Door Lock Driver Right Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Right Doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2607 NO: Go To 3 3. (P392) DOOR LOCK DRIVER RIGHT DOORS WIRE OPEN Disconnect the Passenger Door Latch connector. Measure the resistance of the (P392) Door Lock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P392) Door Lock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G778) DOOR UNLOCK DRIVER RIGHT DOORS WIRE OPEN Measure the resistance of the (G778) Door Unlock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST-VER 1. NO: Repair the (G778) Door Unlock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test RKE Inoperative RKE INOPERATIVE POSSIBLE CAUSES - DTC present Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2608 - Transmitter not programmed - RKE transmitter - Remote keyless entry module Diagnostic Test 1. DTC PRESENT With the DRBIII(R), read DTCs. Attempt to operate the door locks with the RKE transmitter. Q: Does the DRBIII(R) display RKE FOB BATTERY LOW? YES: Refer to symptom RKE FOB BATTERY LOW in this category. NO: Go To 2 2. 9001 TESTER AVAILABLE Q: Do you have access to the Miller Special Tool "9001 RF DETECTOR"? NO: Go To 3 YES: Go To 5 3. TRANSMITTER NOT PROGRAMMED Turn the ignition on. Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarmed Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Try the door locks using the Transmitter. Q: Does the RKE System operate properly? YES: Repair complete. Check with the customer to see if the other transmitters) are operating properly. They may have to be programmed also. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. SUBSTITUTE A KNOWN GOOD TRANSMITTER Secure a known good transmitter. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2609 Lock and Unlock the vehicle using the transmitter. Q: Does the RKE System operate properly? YES: Replace the original transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. TEST TRANSMITTER WITH TESTER Using the 9001 RF Detector, follow the instructions on the back of the tester and test the transmitter several times. Q: Does the signal strength measure "STRONG"? YES: Go To 6. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. PROGRAM RKE TRANSMITTER WITH THE DRBIII(R) Turn the ignition on Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarm Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, then PROGRAM New Fob. Follow the instructions on the screen. Exit PROGRAM RKE. Activate the Door Locks using the RKE Transmitter. NOTE: When repairs are complete, ensure all transmitters used with the vehicle have been programmed. Q: Did the door locks respond properly to the RKE transmitter commands? YES: Repair complete. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Alarm Trips On Its Own ALARM TRIPS ON ITS OWN Diagnostic Test 1. LAST VTSS CAUSE With the DRBIII(R) in Inputs/Outputs, read the Last VTSS Cause state. Q: Were there any causes displayed? YES: Check for a possible intermittent condition with the circuit indicated by the DRBIII(R). Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: The condition that caused this symptom is currently not present. Inspect the related wiring harness for a possible intermittent condition. Look for any chafed, pierced, pinched or partially broken wires. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Cylinder Lock Switch INOP CYLINDER LOCK SWITCH INOP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2610 Cylinder Lock Switch Inop POSSIBLE CAUSES - DTC present - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch MUX circuit open - (G163) Cylinder lock switch MUX wire short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2611 - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Measure the voltage between (G163) Cylinder Lock Switch MUX circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2612 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform Body Verification Test Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2613 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Does Not Trip VTSS DRIVER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the DRIVER DOOR AJAR SW status. Open the driver door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom DRIVER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the driver's door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the driver door lock. Attempt to trip the VTSS by opening the drivers door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2614 Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Headlamps Fail to Flash When Alarm Is Tripped HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster 1. CHECK FCM DTCS AND HIGH BEAM HEADLAMP OPERATION Attempt to operate the exterior lamps with the headlamp switch. With the DRBIII(R), read FCM DTCs. Q: Were there any problems found? YES: Refer to symptom list for problems related to Exterior Lighting. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Horn Fails to Sound When Alarm Is Tripped HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to the Ignition, Power, Accessory category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 2 2. HORN CIRCUIT DIAGNOSTICS Q: Does the horn operate from the horn button? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Refer to symptom Horns Inoperative in the Ignition, Power, Accessory category. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Left Rear Door Does Not Trip VTSS (4 Door) LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2615 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Left Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom LEFT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the left rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the left rear door lock. Attempt to trip the VTSS by opening the left rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Does Not Trip VTSS PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the passenger door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom PASSENGER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the passenger door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the passenger door lock. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2616 Attempt to trip the VTSS by opening the passenger door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Does Not Trip VTSS (4 Door) RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Right Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom RIGHT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the right rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the right rear door lock. Attempt to trip the VTSS by opening the right rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2617 NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test VTSS Will Not Arm Properly VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster 1. ATTEMPT TO ENABLE THE VTSS Turn the ignition Off to the lock position. Disconnect the battery negative cable wait 5 seconds then reconnect battery cable. Turn the ignition to the On position for 10 seconds, then back Off to the lock position and remove key. Close all doors. Using the key, lock the vehicle with the Driver Door Cylinder Lock Switch and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Go To 2 NO: Go To 3 2. VTSS NOT ENABLED Unlock the vehicle to disarm the VTSS. Ensure all doors are closed. Using the RKE key fob, lock the vehicle and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Test Complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. USE DRB TO COMMUNICATE WITH THE SKIM With the DRBIII(R), attempt to communicate with the SKIM. Q: Does the DRBIII(R) communicate with the SKIM? YES: Go To 4 NO: Refer to communication category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 4. DTC OR VTSS INHIBITORS Ensure the doors are closed. With the DRBIII(R), read the active DTC's and the ajar switch states. Q: Does the DRBIII(R) display any closed switches or related DTC's? YES: Refer to the Symptom List and diagnose the appropriate symptom in the DOOR AJAR or related category. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 5 5. CYLINDER LOCK SWITCH CIRCUIT OPEN Turn the ignition on. With the DRBIII(R), read the Driver Cylinder Lock Switch MUX volts while turning the key in the driver door lock cylinder. Q: Did the MUX voltage change from approximately 5.0 volts to 4.0 for lock and 2.4 for unlock? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2618 YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. INSTRUMENT CLUSTER CYLINDER LOCK SWITCH VOLTAGE LOW Disconnect the Cylinder Lock Switch connector. Measure the voltage between Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 7 NO: Go To 8 7. CYLINDER LOCK SWITCH GROUND OPEN Disconnect the Cylinder Lock Switch connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Ground circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 8. CYLINDER LOCK SWITCH MUX OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2619 Disconnect the Cylinder Lock Switch connector. Disconnect the Instrument Cluster C2 connector. Measure the resistance of the Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Cylinder Lock Switch Mux circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2623 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2624 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2625 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2626 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2631 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2632 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2633 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2634 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2635 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Connector Views Data Link Connector Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2641 Data Link Connector: Description and Operation The Data Link Connector (DLC) (3) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the stamped metal lower instrument panel reinforcement (2), just below the lower edge of the instrument panel steering column opening cover (1). The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Programmable Communications Interface (PCI) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network within the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling Electronic Throttle Actuator: Technical Service Bulletins Safety Systems - Inadvertent Damage/Disabling NUMBER: 08-027-04 GROUP: Electrical DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-017-01, DATED SEPTEMBER 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND YEARS. SUBJECT: Safety Systems - Vehicle Modifications/Repair MODELS: 2002 - **2003** (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2002 (BR/BE) Ram Pickup **2004 - 2005 (CS) Pacifica** 2002 - **2003** (DN) Durango **2003 - 2005 (DR/DH) Ram Pickup** **2004 - 2005 (HB) Durange 2002 - **2005** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 - **2005** (KJ) Liberty 2002 - **2004** (LH) Concorde/Intrepid/300M **2005 (LX) 300/Magnum ** **2005 (ND) Dakota** 2002 (PG) PT Cruiser (International Markets) 2002 - **2005** (PL) Neon 2002 - **2003** (PR) Prowler 2002 - **2005** (PT) Chrysler PT Cruiser 2002 - **2005** (RS) Town & Country/Caravan/Voyager 2002 - **2005** (RG) Chrysler Voyager (International Markets) 2002 (SR) Viper 2002 - **2005** (ST) Sebring Coupe/Stratus Coupe 2002 - **2005** (TJ) Wrangler **2002 - 2005 (VA) Sprinter** 2002 - **2004** (WJ) Grand Cherokee **2005 (WK) Grand Cherokee** Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling > Page 2646 2002 - **2004** (WG) Grand Cherokee (International Markets) **2005 (WH) Grand Cherokee (International Markets)** **2003 - 2005 (ZB) Viper** **2004 - 2005 (ZH) Crossfire** DISCUSSION: Current DaimlerChrysler vehicles may contain any or all of the following safety Systems: driver airbags, passenger airbags, side curtain airbags, side seat airbags, seat belt pre-tensioners, anti-lock brakes, electronic throttle control, or traction control. All these systems contain multiple sophisticated sensitive electrical and mechanical components. The location and function of all safety system components must be determined before performing repairs; including accident, mechanical or electrical, or vehicle modifications such as adding an after-market sunroof. WARNING: ANY INADVERTENT SAFETY SYSTEM COMPONENT OR ASSOCIATED WIRING DAMAGE/MODIFICATION OR COMPONENT LOCATION CHANGE MAY DISABLE ANY OF THE SAFETY SYSTEMS. Refer to the appropriate vehicle Service Information to determine location and function of all safety systems before servicing vehicle. All systems should be checked for functionality after the vehicle modifications/repairs are complete. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation Electronic Throttle Control Indicator: Description and Operation An Electronic Throttle Control (ETC) indicator is standard equipment on all gasoline engine instrument clusters. However, on vehicles not equipped with the I/I optional 5.7 liter gasoline engine, this indicator is electronically disabled. The ETC indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Electronic Throttle Control" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system is faulty or inoperative. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ETC indicator is illuminated for about six seconds. The entire six second bulb test is a function of the PCM. - ETC Lamp-On Message - Each time the cluster receives a lamp-on message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about twelve seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. - Communication Error - If the cluster receives no ETC lamp messages for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected a system malfunction and/or that the ETC system is inoperative. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, the instrument cluster and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ETC indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: Customer Interest Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2658 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2659 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: All Technical Service Bulletins Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2665 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2666 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2671 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2672 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2673 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2674 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2675 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2676 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2677 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2678 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2679 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 2680 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2685 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2686 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2687 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2698 Engine Control Module: Locations Right Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2699 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Module-Engine Control C1 Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2702 Module-Engine Control C1 Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2703 Module-Engine Control C1 Part 3 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2704 Module-Engine Control C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2705 Module-Powertrain Control C1 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2706 Module-Powertrain Control C2 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2707 Module-Powertrain Control C3 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2708 Module-Powertrain Control C4 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2711 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2712 Engine Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2713 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2714 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2715 Engine Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2716 Engine Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2717 Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2718 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2719 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2720 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 2721 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming Engine Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2724 Engine Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2725 Engine Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2726 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2727 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 2732 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2733 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2734 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 2738 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL The IAC motor is not serviceable on the 5.7L V-8 engine. INSTALLATION The IAC motor is not serviceable on the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2743 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2744 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2745 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2750 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2751 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2752 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2753 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2754 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2755 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2756 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2757 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-2 (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 8w-18-3 (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 8w-18-4 (Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 8w-18-5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 8w-18-6 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2768 Information Bus: Description and Operation The DaimlerChrysler Programmable Communication Interface (PCI) data bus system is a single wire multiplex system used for vehicle communications on many DaimlerChrysler Corporation vehicles. Multiplexing is a system that enables the transmission of several messages over a single channel or circuit. All DaimlerChrysler vehicles use this principle for communication between various microprocessor-based electronic control modules. The PCI data bus exceeds the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. Many of the electronic control modules in a vehicle require information from the same sensing device. In the past, if information from one sensing device was required by several controllers, a wire from each controller needed to be connected in parallel to that sensor. In addition, each controller utilizing analog sensors required an Analog/Digital (A/D) converter in order to "read" these sensor inputs. Multiplexing reduces wire harness complexity, sensor current loads and controller hardware because each sensing device is connected to only one controller, which reads and distributes the sensor information to the other controllers over the data bus. Also, because each controller on the data bus can access the controller sensor inputs to every other controller on the data bus, more function and feature capabilities are possible. In addition to reducing wire harness complexity, component sensor current loads and controller hardware, multiplexing offers a diagnostic advantage. A multiplex system allows the information flowing between controllers to be monitored using a diagnostic scan tool. The DaimlerChrysler system allows an electronic control module to broadcast message data out onto the bus where all other electronic control modules can "hear" the messages that are being sent. When a module hears a message on the data bus that it requires, it relays that message to its microprocessor. Each module ignores the messages on the data bus that are being sent to other electronic control modules. Data exchange between modules is achieved by serial transmission of encoded data over a single wire broadcast network. The wire colors used for the PCI data bus circuits are yellow with a violet tracer, or violet with a yellow tracer, depending upon the application. The PCI data bus messages are carried over the bus in the form of Variable Pulse Width Modulated (VPWM) signals. The PCI data bus speed is an average 10.4 Kilo-bits per second (Kbps). By comparison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kbps. The voltage network used to transmit messages requires biasing and termination. Each module on the PCI data bus system provides its own biasing and termination. Each module (also referred to as a node) terminates the bus through a terminating resistor and a terminating capacitor. There are two types of nodes on the bus. The dominant node terminates the bus through a 1 KW resistor and a 3300 pF capacitor. The Powertrain Control Module (PCM) is the only dominant node for the PCI data bus system. A standard node terminates the bus through an 11 KW resistor and a 330 pF capacitor. The modules bias the bus when transmitting a message. The PCI bus uses low and high voltage levels to generate signals. Low voltage is around zero volts and the high voltage is about seven and one-half volts. The low and high voltage levels are generated by means of variable-pulse width modulation to form signals of varying length. The Variable Pulse Width Modulation (VPWM) used in PCI bus messaging is a method in which both the state of the bus and the width of the pulse are used to encode bit information. A "zero" bit is defined as a short low pulse or a long high pulse. A "one" bit is defined as a long low pulse or a short high pulse. A low (passive) state on the bus does not necessarily mean a zero bit. It also depends upon pulse width. If the width is short, it stands for a zero bit. If the width is long, it stands for a one bit. Similarly, a high (active) state does not necessarily mean a one bit. This too depends upon pulse width. If the width is short, it stands for a one bit. If the width is long, it stands for a zero bit. In the case where there are successive zero or one data bits, both the state of the bus and the width of the pulse are changed alternately. This encoding scheme is used for two reasons. First, this ensures that only one symbol per transition and one transition per symbol exists. On each transition, every transmitting module must decode the symbol on the bus and begin timing of the next symbol. Since timing of the next symbol begins with the last transition detected on the bus, all of the modules are re-synchronized with each symbol. This ensures that there are no accumulated timing errors during PCI data bus communication. The second reason for this encoding scheme is to guarantee that the zero bit is the dominant bit on the bus. When two modules are transmitting simultaneously on the bus, there must be some form of arbitration to determine which module will gain control. A data collision occurs when two modules are transmitting different messages at the same time. When a module is transmitting on the bus, it is reading the bus at the same time to ensure message integrity. When a collision is detected, the module that transmitted the one bit stops sending messages over the bus until the bus becomes idle. Each module is capable of transmitting and receiving data simultaneously. The typical PCI bus message has the following four components: - Message Header - One to three bytes in length. The header contains information identifying the message type and length, message priority, target module(s) and sending module. - Data Byte(s) - This is the actual message that is being sent. - Cyclic Redundancy Check (CRC) Byte - This byte is used to detect errors during a message transmission. - In-Frame Response (IFR) byte(s) - If a response is required from the target module(s), it can be sent during this frame. This function is described in greater detail in the following paragraph. The IFR consists of one or more bytes, which are transmitted during a message. If the sending module requires information to be received immediately, the target module(s) can send data over the bus during the original message. This allows the sending module to receive time-critical information without having to wait for the target module to access the bus. After the IFR is received, the sending module broadcasts an End of Frame (EOF) message and releases control of the bus. The PCI data bus can be monitored using a diagnostic scan tool. It is possible, however, for the bus to pass all diagnostic scan tool tests and still be faulty if the voltage parameters are all within the specified range and false messages are being sent. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2772 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2773 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2774 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2775 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 2781 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2782 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2783 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2784 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC's, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. On vehicles with a diesel engine, the ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2791 Sensor-Map (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2792 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2793 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2794 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counter-clockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2795 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2804 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2805 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2806 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2807 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2813 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2814 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2815 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 2816 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2819 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2820 Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2821 Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2822 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (3.7L/5.7L) Sensor-Oxygen-Left Rear (3.7L/5.7L LD) Sensor-Oxygen-Left Rear (5.7L HD) Sensor-Oxygen-Right Front (3.7L/5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2823 Sensor-Oxygen-Right Rear (3.7L/5.7L LD) Sensor-Oxygen-Right Rear (5.7L HD) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2824 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2825 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2826 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2830 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2834 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2835 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2836 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation Body Control Module: Description and Operation The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2843 Body Control Module: Symptom Related Diagnostic Procedures Air Bag System AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems Diagnostic Test 1. AIRBAG WARNING INDICATOR ON WITHOUT ACTIVE TROUBLE CODES NOTE: Ensure the battery is fully charged. Turn the ignition on. Make sure that all active DTC's have been repaired before performing this procedure. With the DRBIII(R) read the WARNING LAMP STATES. Q: With no active DTCs, Does the LAMP REQ by ACM monitor show ON? YES: Go To 2 NO: Perform ORC VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test 2. REPLACE THE ORC WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER (ORC) IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. NOTE: When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected. Repair Replace the ORC. Perform ORC VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test NOTE: When reconnecting Airbag system components, the ignition must be turned off and the battery must be disconnected. Audio System Audio System Diagnosis Table Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2844 Audio System Diagnosis Table Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2845 Audio System Diagnosis Table Part 3 Of 3 Any diagnosis of the Audio system should begin with the use of a scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Chime Inoperative CHIME INOPERATIVE POSSIBLE CAUSES - Cluster Diagnostic Test 1. ACTUATE THE CHIME WITH THE DRBIII Turn the ignition on. Close the doors. With the DRBIII(R) select: Electro/Mech Cluster and actuate the Chime. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2846 Q: Does the chime sound when actuated by the DRBIII(R)? YES: If the chime operates as it should, check for other reasons that the chime is being inoperative. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Sounds With Drivers Door Open and Key Removed From Ignition CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2847 Chime Sounds With Driver Door Open Key Removed POSSIBLE CAUSES - Key-in IGN SW status - Ignition switch shorted - (G26) Key-in ignition sw sense short to ground - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2848 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: Ensure the exterior lamps turn on and off properly and are off before continuing this test. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Remove the key from the ignition switch. Q: Does the DRBIII(R) show Key-In IGN OPEN? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. KEY-IN IGN SWITCH SHORTED Disconnect the Ignition Switch connector. Q: Did the chime turn off? YES: Check the Ignition Lock Cylinder for damage. If OK replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2849 3. (G26) KEY-IN IGNITION SWITCH SENSE WIRE SHORT TO GROUND Turn ignition off. Disconnect the Ignition Switch connector. Disconnect the Cluster C3 connector. Measure the resistance of the (G26) Key-in Ignition Switch Sense circuit to ground at the Ignition Switch connector. Q: Is the resistance below 100.0 ohms? YES: Repair the (G26) Key-In Ignition Switch Sense wire for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Warning System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2850 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2851 WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired chime warning system inputs to the ElectroMechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and methods. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Programmable Communications Interface (PCI) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Key In Ignition and Drivers Door Open Chime Inoperative KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2852 Key In Ignition And Driver's Door Open Chime Inoperative POSSIBLE CAUSES - (Z42) Ground open - (G26) Key-in ignition switch open - Ignition switch - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2853 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: The driver's door ajar switch must be operational for the result of this test to be valid. Ensure that the Key is still in the Ignition Switch. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Q: Does the DRBIII(R) show Key-In IGN CLOSED? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. IGNITION SWITCH GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch connector. Turn all lights off. Measure the resistance between ground and the (Z42) Ground circuit in the ignition switch harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2854 NO: Repair the (Z42) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. IGNITION SWITCH OPEN Connect the ignition switch connector if disconnected. Turn ignition on. With the ignition switch connector connected, back jumper the (G26) Key-In Ignition Switch Sense circuit to ground at the ignition switch connector. With the DRBIII(R), enter Instrument Cluster Input/Outputs and observe the Key-In IGN SW status. Q: Does the DRBIII display Key-In IGN SW: Closed? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. KEY-IN IGNITION SWITCH SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch harness connector. Disconnect the Cluster C3 harness connector. Measure the resistance of the (G26) Key-In Ignition Switch Sense circuit between the ignition switch connector and the Instrument Cluster C3 connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2855 Q: Is the resistance below 5.0 ohms? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G26) Key-In Ignition Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Vehicle Speed Warning Chime Problem VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in cluster - Cluster Diagnostic Test 1. WITH THE DRBIII CHECK THE COUNTRY CODE SETTING NOTE: The high speed warning chime is for Gulf Coast Countries only. Turn the ignition on. With the DRBIII(R) in Miscellaneous check the Cluster country code setting. Q: Is the country code incorrect? YES: Program the correct country code. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Heater Control Illumination Inoperative A/C HEATER CONTROL ILLUMINATION INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2856 A/C Heater Control Illumination Inoperative POSSIBLE CAUSES - Faults present in the cluster (MIC) - (E16) Panel lamps driver circuit open - Bulb(s) - filament open (single-zone HVAC module only) - Cluster (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2857 - A/C Heater control Diagnostic Test 1. CHECK FOR DTCs IN THE CLUSTER (MIC) Turn the ignition on. With the DRBIII(R), read Cluster DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. TEST (E16) PANEL LAMPS DRIVER CIRCUIT USING A TEST LIGHT Turn the Headlamp switch on. Rotate the Cargo Dome switch to the full brightness setting. CAUTION: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (E16) Panel Lamps Driver circuit in the A/C Heater Control C1 harness connector. Q: Does the test light illuminate brightly? YES: (Dual-Zone Systems) Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: (Single-Zone Systems) Go To 3 NO: Go To 4 3. INSPECT THE INOPERATIVE BULB(S) Turn the ignition off. Remove the inoperative bulb(s) from the A/C Heater Control. NOTE: If necessary, hold the bulb in front of a lamp to see the filament. Inspect the bulb(s). Q: Is each inoperative bulb Ok? YES: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the inoperative bulb(s). Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2858 Tests and Associated Procedures/Verification Tests/Body Verification Test 4. CHECK (E16) PANEL LAMPS DRIVER CIRCUIT FOR AN OPEN Disconnect the A/C Heater Control C1 harness connector. Disconnect the Cluster C1 harness connector. Measure the resistance of the (E16) Panel Lamps Driver circuit between the A/C Heater Control C1 harness connector and the Cluster C1 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (E16) Panel Lamps Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Flashing A/C STATUS INDICATOR FLASHING Theory of Operation Running the AC Cooldown test will cause the A/C status indicator to flash. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. When the A/C status indicator is flashing, it will not indicate A/C operating status. However, the A/C mode switch will continue to function normally. For vehicles equipped with EBL, when the A/C status indicator is flashing, the EBL status indicator will not function. However, the EBL mode switch will continue to function normally. POSSIBLE CAUSES - A/C Cooldown test failed 1. PERFORM THE A/C COOLDOWN TEST NOTE: The following are prerequisites of the Cooldown Test. Verify each of the following before running the test: - Verify that no Evaporator Temperature Sensor related DTCs are not active. If active, diagnose and repair the DTC before proceeding. - Verify that the refrigerant system has an adequate charge. Check and repair as necessary before proceeding. - Verify that the blower motor operates correctly in all speeds. Diagnose and repair all blower related faults before proceeding. - Verify that the work area ambient temperature is above 21.1° C (70° F) before proceeding. Move the vehicle to a warmer work area if necessary. - Verify that the evaporator temperature is above 12.7° C (55° F) before proceeding. - Verify that the Mode Select control is set to the panel position. - Verify that the A/C compressor is not running. If the compressor is running, turn the A/C off and allow the evaporator to warm up before proceeding. Start the engine. Turn the Blower control to the high speed position. With the DRBIII(R) in HVAC, select System Tests and then select AC Cooldown test. Allow one minute for the test to complete. One or more Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2859 status messages will display on the DRBIII(R) after running the AC Cooldown Test. These messages will clear after paging back out of this test function. Therefore, it is important to note all messages before doing so. Q: Does the DRBIII(R) display a status message that indicates a fault has occurred? Yes, Blower Not On High Diagnose and repair the fault. Refer to Blower Not On High for the diagnostic test procedure. Yes, Cooldown Test Sensor Failure Diagnose and repair the fault. Refer to Cooldown Test Sensor Failure for the diagnostic test procedure. Yes, Cooldown Time Excessive Fault Diagnose and repair the fault. Refer to Cooldown Time Excessive Fault for the diagnostic test procedure. Yes, Cooldown Test Too Cold To Start Diagnose and repair the fault. Refer to Cooldown Test Too Cold To Start for the diagnostic test procedure. NO: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW A/C STATUS INDICATOR WILL NOT ILLUMINATE - A/C HEATER CONTROL WITHOUT EBL SW Theory of Operation Failing recalibration will prevent the A/C status indicator from operating but still allows the A/C mode switch to function normally. This test verifies if the status indicator is inoperable due to either a recalibration failure or a fault with the status indicator. POSSIBLE CAUSES - HVAC door recalibration failed - A/C Heater control Diagnostic Test 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Failed? YES: Diagnose and repair the fault(s). NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Dual-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2860 Actuator Circuit Test Diagnostics (Dual-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2861 messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test fault message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2862 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2863 Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2864 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2865 VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2866 VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C29) Mode Door 2 Driver circuit and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C33) Passenger Blend Door Driver circuit for a short to the (C29) Mode Door 2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 12 12. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2867 Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 13 NO: Go To 14 13. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 14. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Single-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2868 Actuator Circuit Test Diagnostics (Single-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2869 shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2870 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. RUN THE ACTUATOR CIRCUIT TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2871 Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2872 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2873 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C29) Mode Door 2 Driver circuit for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2874 11. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 12 NO: Go To 13 12. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2875 VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 13. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Dual-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2876 Blend/Mode/Recirc Door Operation Improper (Dual-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2877 - Door(s) bound up, warped, worn, damaged - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Passenger Blend Door Function Test Go To 6 Driver Blend Door Function Test Go To 7 Recirculation Door Function Test Go To 8 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2878 Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK PASSENGER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Passenger Blend control to the full hot position. Move the Passenger Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the passenger's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Passenger Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK DRIVER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Driver Blend control to the full hot position. Move the Driver Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the driver's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Driver Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Single-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2879 Blend/Mode/Recirc Door Operation Improper (Single-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open - Door(s) bound up, warped, worn, damaged Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2880 - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Blend Door Function Test Go To 6 Recirculation Door Function Test Go To 7 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2881 YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Blend control to the full hot position. Move the Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Motor Inoperative (Except SRT10) BLOWER MOTOR INOPERATIVE (EXCEPT SRT10) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2882 Blower Motor Inoperative (Except SRT10) POSSIBLE CAUSES - (C7) Blower motor feed circuit shorted to ground - (A970) Fused B(+) circuit shorted to ground - (C70) Blower motor high driver circuit open - (Z134) Ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2883 - (C7) Blower motor feed circuit open - (A970) Fused B(+) circuit open - IPM fuse #4 open - Blower motor - Ignition switch - A/C heater control Diagnostic Test 1. CHECK THE FUSE Turn the ignition off. Remove and inspect IPM Fuse #4. Q: Is the fuse open? YES: Replace IPM Fuse #4 and Go To 2. NO: Reinstall IPM Fuse #4 and Go To 5. 2. CHECK BLOWER MOTOR OPERATION Turn the ignition on. Turn the blower on and operate it in all speeds and modes. Q: Does the blower motor operate properly without blowing the fuse? YES: Check the (C7) Blower Motor Feed circuit and the (A970) Fused B(+) circuit for an intermittent short to ground. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2884 Turn the ignition off. Disconnect the Blower Motor harness connector. Measure the resistance of the (C7) Blower Motor Feed circuit between ground and the Blower Motor harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C7) Blower Motor Feed circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (A970) FUSED B(+) CIRCUIT FOR A SHORT TO GROUND Disconnect the Ignition Switch harness connector. Measure the resistance of the (A970) Fused B(+) circuit between ground and the Ignition Switch harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (A970) Fused B(+) circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor and fuse. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2885 Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Blower Motor harness connector. Q: Does the test light illuminate brightly? YES: Go To 6 NO: Go To 9 6. CHECK BLOWER MOTOR OPERATION BY BYPASSING THE A/C HEATER CONTROL Turn the ignition off. Connect a jumper wire between ground and the (C70) Blower Motor High Driver circuit in the Blower Motor harness connector. Turn the ignition on. Q: Does the blower motor run at high speed? YES: Go To 7 NO: Replace the Blower Motor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2886 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor harness connector. Measure the resistance of the (C70) Blower Motor High Driver circuit between the A/C Heater Control C2 harness connector and the Blower Motor harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 8 NO: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (Z134) GROUND CIRCUIT FOR AN OPEN Measure the resistance of the (Z134) Ground circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the A/C Heater Control. NO: Repair the (Z134) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2887 NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Repair the (C7) Blower Motor Feed circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (A970) FUSED B(+) CIRCUIT FOR AN OPEN NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (A970) Fused B(+) circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (A970) Fused B(+) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Speed Does Not Correspond With Control Setting Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2888 BLOWER SPEED DOES NOT CORRESPOND WITH CONTROL SETTING Blower Speed Does Not Correspond With Control Setting POSSIBLE CAUSES - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2889 - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to voltage - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted together - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit open - Blower motor resistor block open - A/C heater control Diagnostic Test 1. CHECK IF THE BLOWER MOTOR RUNS WITH THE BLOWER CONTROL IN THE OFF POSITION Turn the Blower control to the Off position. Turn the ignition on. Q: Does the blower motor run? YES: Go To 2 NO: Go To 3 2. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms on any of the circuits? YES: Repair all circuits with a resistance below 10K ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2890 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Does the test light illuminate brightly on each circuit? YES: Go To 4 NO: Go To 8 4. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the voltage of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is there voltage present on any of the circuits? YES: Repair all circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: GO TO 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2891 5. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR A SHORT TO THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C71) Blower Motor Low Driver circuit and the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C71) Blower Motor Low Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C71) Blower Motor Low Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR A SHORT TO THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C73) Blower Motor M2 Driver circuit and the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C73) Blower Motor M2 Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C73) Blower Motor M2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR A SHORT TO THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2892 Measure the resistance between the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C72) Blower Motor M1 Driver circuit for a short to the (C70) Blower Motor High Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 9 NO: Repair the (C71) Blower Motor Low Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2893 Measure the resistance of the (C73) Blower Motor M2 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 10 NO: Repair the (C73) Blower Motor M2 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR AN OPEN Measure the resistance of the (C72) Blower Motor M1 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 11 NO: Repair the (C72) Blower Motor M1 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 11. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2894 Measure the resistance of the (C70) Blower Motor High Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor Resistor Block. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test EBL Status Indicator Flashing EBL STATUS INDICATOR FLASHING Theory of Operation Running the HVAC Door Recalibration will cause the EBL status indicator to flash. If recalibration fails, the status indicator will continue to flash until either the system passes recalibration or the ignition key is cycled. When the EBL status indicator is flashing, it will not indicate EBL operating status. However, the EBL mode switch will continue to function normally. When the EBL status indicator is flashing, the A/C status indicator will not function. However, the A/C mode switch will continue to function normally. POSSIBLE CAUSES - HVAC door recalibration failed 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Passed? YES: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Diagnose and repair the fault(s). Horn HORNS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2895 Horns Inoperative POSSIBLE CAUSES - DTC present - Fuse #45 - Horns - Horn ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2896 - Horn relay output circuit open - Horn switch - Horn switch ground - Clockspring - Horn switch sense open - Integrated power module - Instrument cluster - Front control module Diagnostic Test 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to symptom list. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. ACTUATE HORN RELAY With the DRBIII(R), actuate the Horn Relay. Q: Do the horns operate? YES: Go To 3 NO: Go To 7 3. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch. Measure the resistance of the Horn Switch ground circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the horn switch ground as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch connector. WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the Horn switch connector and ground. Q: Did the horns sound? YES: Replace the horn switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CLOCKSPRING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2897 Turn the ignition off. Disconnect the clockspring C1 connector. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the clockspring connector and ground. Q: Did the horns sound? YES: Replace the clockspring. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. HORN SWITCH SENSE Turn the ignition off. Disconnect the clockspring C1 connector. Disconnect the Instrument Cluster C3 connector. NOTE: Check connectors - Clean/repair as necessary. Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Instrument Cluster C3 connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Horn Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2898 7. CHECK FUSE #45 Turn the ignition off. Using a 12-volt test light connected to ground, check the Horn fuse #45 in the IPM. Q: Is the fuse open? YES: Replace the fuse. Check for a short to ground in the Horn Relay Output circuit from the IPM to the horns. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. HORN RELAY OUTPUT Disconnect a horn connector. With the DRBIII(R), actuate the Horn Relay. Using a 12-volt test light connected to ground, check the Horn Relay Output circuit. Q: Does the test light illuminate brightly? YES: Go To 9 NO: Go To 10 9. HORN GROUND CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2899 Turn the ignition off. Disconnect the Horn connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit in the horn connector. Q: Does the test light illuminate brightly? YES: Replace the Horns. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Ground circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. HORN RELAY OUTPUT CIRCUIT OPEN Gain access to the IPM C1 connector. Using a 12-volt test light connected to ground, back probe the Horn Relay Output circuit in the IPM C1 connector. Turn the ignition on. With the DRBIII(R), the actuate the horn relay. Q: Does the test light illuminate brightly? YES: Repair the Horn Relay Output circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2900 11. INTEGRATED POWER MODULE Turn the ignition off. Remove the Front Control Module from the Integrated Power Module. NOTE: - Check connectors - Clean/repair as necessary. - The test light is still connected to the C1 connector. Momentarily jumper the Horn Relay Control circuit to ground at the FCM connector. Q: Does the test light illuminate brightly? YES: Replace the Front Control Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Integrated Power Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test All Gauges Inoperative ALL GAUGES INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2901 All Gauges Inoperative POSSIBLE CAUSES - No response - PCI BUS - No response - PCI BUS - powertrain control module - PCI BUS - instrument cluster - (F21) Fused ignition switch output (run/start) circuit short to ground - (F1) Fused ignition switch output (off/run/start) circuit short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2902 - (F21) Fused ignition switch output (run/start) circuit open - (F1) Fused ignition switch output (off/run/start) circuit open - (Z18) Instrument cluster ground circuit for an open - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS NOTE: Diagnose and repair any MIC, PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test. Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), select Body, MIC, SYSTEM TESTS, PCM Monitor. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PCI BUS - INSTRUMENT CLUSTER Turn the ignition on. With the DRBIII(R), select Body, MIC, MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Inspect the #20 Fuse in the PDC. If the fuse is open, replace with proper rated fuse. Turn the ignition on for one minute. Turn the ignition off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2903 Inspect the #20 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F21) Fused Ignition Switch Output (Unlock/Run) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. If the fuse is open, replace with the proper rated fuse. Turn the ignition on for 1 minute. Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F1) Fused Ignition Switch Output (Run/Start) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2904 Q: Is the voltage below 10.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F1) Fused Ignition Switch Output (Off/Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F1) Fused Ignition Switch Output (Off/Run/ Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (Z18) Instrument Cluster Ground circuit. Q: Is the resistance below 5.0 ohms? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2905 NO: Repair the (Z18) Instrument Cluster Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Any PCI Indicator Inoperative ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - Indicator message not received - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - INSTRUMENT CLUSTER With the DRBIII(R), select MIC, then MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE INSTRUMENT CLUSTER. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. NO RESPONSE - PCI BUS With the DRBIII(R), select Body, MIC, MONITORS, PCI BUS MONITORS. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE POWERTRAIN CONTROL MODULE. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. INDICATOR MESSAGE NOT RECEIVED NOTE: Diagnose and repair any PCM or BCM DTCs before proceeding with this test. Perform the Instrument Cluster Self Test. Depress and hold the Trip Odometer button while turning the ignition from the off to the on position. Observe the indicator in question. Q: Did the indicator illuminate? YES: Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Always On BRAKE WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2906 Brake Warning Indicator Always On POSSIBLE CAUSES - (B20) Brake fluid level sensor sense circuit short to ground - (B25) Park brake switch sense circuit short to ground - Brake fluid level sensor - Park brake switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2907 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. BRAKE FLUID LEVEL SENSOR NOTE: Diagnose and repair any MIC, Brake, or Communication DTCs before proceeding with this test. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance of the Brake Fluid Level Sensor between pin 1 and pin 2. Q: Does the resistance measure less than 900 ohms? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance between ground and the (B20) Brake Fluid Level Sensor Sense circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2908 Q: Is the resistance below 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PARK BRAKE SWITCH Turn the ignition off. Disconnect the Park Brake Switch harness connector. Turn the ignition on. Observe the Brake warning indicator. Q: Did the Brake warning indicator illuminate briefly and then turn off? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. (B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Park Brake Switch harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2909 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (B25) Park Brake Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. ANTI-LOCK BRAKES MODULE Turn the ignition off. Reconnect any harness connector(s) that were previously disconnected. Turn the ignition on. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Inoperative BRAKE WARNING INDICATOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2910 Brake Warning Indicator Inoperative POSSIBLE CAUSES - (Z420) Brake fluid level sensor ground circuit open - (B25) Park brake switch sense circuit open - (B20) Brake fluid level sense circuit open - Park brake switch - Brake fluid level sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2911 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. FAULT LOCATION NOTE: Diagnose and repair any MIC, ABS, or Communication DTCs before proceeding with this test. Q: Is the Brake warning indicator only inoperative using the Park Brake? YES: Go To 2 NO: Go To 4 2. PARK BRAKE SWITCH Disconnect the Park Brake Switch harness connector. Connect a jumper wire between the (B25) Park Brake Switch Sense circuit and ground. Turn the ignition on. Observe the BRAKE indicator. Q: Did the BRAKE indicator illuminate? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2912 Turn the ignition off. Disconnect the (B25) Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (B25) Park Brake Switch Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. BRAKE FLUID LEVEL SENSOR Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Q: Does the Brake warning indicator illuminate? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2913 5. (Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance between ground and the (Z420) Brake Fluid Level Sensor Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z420) Brake Fluid Level Sensor Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. (B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance of the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2914 NO: Go To 7 7. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Anti-lock Brakes Module harness connector. Connect a jumper wire between the (B25) Brake Fluid Level Sensor Sense circuit and ground. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Fuel Gauge Inaccurate FUEL GAUGE INACCURATE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2915 Fuel Gauge Inaccurate POSSIBLE CAUSES - Fuel level sensor wiring - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2916 1. DTC PRESENT NOTE: Diagnose and repair any PCI Bus problems before proceeding with this test. Turn the ignition on. With the DRBIII(R), read the PCM DTCs. Q: Does the DRBIII(R) display any Fuel Level Sensor related DTC? YES: Refer to the Powertrain Diagnostic Information for the related symptom(s). Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test as follows: Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the Fuel Gauge during the Self Test. The Fuel Gauge pointer should pause at each of these following positions: E, 1/4, 1/2, 3/4, Full, and back to E. Q: Does the Fuel Gauge function as described above? YES: Go To 3 NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. FUEL LEVEL SENSOR WIRING Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Disconnect the PCM C2 and C3 harness connectors. Measure the resistance of the (N4) Fuel Level Sensor Signal circuit between the Fuel Pump Module harness connector and the PCM harness connector. Measure the resistance of the (K900) Sensor Ground circuit between the Fuel Pump Module harness connector and the PCM harness connector. Q: Is the resistance below 5.0 ohms on both circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2917 YES: Replace the Fuel Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the circuits with a resistance above 5.0 ohms for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Gauge Inoperative - Gas Engines ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module - Instrument cluster DIAGNOSTIC TEST 1. POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any PCM DTCs? YES: Refer to the DRIVEABILITY category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Perform the Instrument Cluster Self Test. NOTE: The Self Test can be initiated manually by depressing and holding the Trip Reset button while turning the ignition on, or by using the DRBIII(R). Observe the gauge in question while the Instrument Cluster performs the Self Test. The gauges should position at the following calibrations points: Speedometer MPH: 0, 20, 60, 90 Tachometer Gas: 0, 1000, 3000, 6000 Fuel: E, 1/4, 1/2, 3/4, F Coolant: Cold, 1/4, 1/2, 3/4, HI Volts: 6, 9, 12, 15, 17 Q: Did the gauge in question operate properly? YES: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wire harness. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test PRNDL Not Displaying Correct Position (EATX Vehicles) PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster DIAGNOSTIC TEST 1. DTC PRESENT NOTE: - Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle. - Ensure that there is communication between the Cluster and PCM before proceeding with this test. - Diagnose and repair any DTCs before proceeding with this test. - Ensure that the PCM passes the Shift Lever Test with the DRBIII(R) before proceeding with this test. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2918 Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any MIC or PCM DTCs? YES: Refer to the correct symptom list for problems related to DTCs. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test. Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the PRNDL display during the Self Test. Q: Did any part of the VF display fail to illuminate? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wiring harness, refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off SEAT BELT WARNING INDICATOR ALWAYS OFF Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2919 Seat Belt Warning Indicator Always Off POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster Diagnostic Art Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2920 1. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2921 Seat Belt Warning Indicator Always Off - Standard Cab POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2922 1. (G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on SEAT BELT WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2923 Seat Belt Warning Indicator Always On POSSIBLE CAUSES - (Z951) Seat belt switch ground circuit for an open - (G10) Seat belt switch sense circuit open - Seat belt switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2924 DIAGNOSTIC TEST 1. CHECK THE OPERATION OF THE SEAT BELT SWITCH Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate for approximately 4 seconds and then turn off? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Measure the resistance between ground and the (Z951) Seat Belt Switch Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2925 Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2926 Seat Belt Warning Indicator Always On - Standard Cab POSSIBLE CAUSES - (F983) Fused ignition switch output (run-acc) circuit open - (Z951) Seat belt switch ground circuit open - (G10) Seat belt switch sense circuit open - Seat belt tensioner reducer Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2927 - Seat belt switch - Instrument cluster 1. (F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN Turn the ignition off. Disconnect the Seat Belt Tensioner Reducer harness connector. Turn the ignition on. Measure the voltage between the (F983) Fused Ignition Switch Output (Run-Acc) circuit and ground in the Tensioner Reducer harness connector. Q: Is the voltage above 10.5 volts? YES: Go To 2 NO: Repair the (F983) Fused Ignition Switch Output (Run-Acc) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. SEAT BELT TENSIONER REDUCER Ensure that the Seat Belt Tensioner Reducer harness connector is connected. Measure the voltage between the (G10) Seat Belt Switch Sense circuit and ground in the Seat Belt Tensioner Reducer harness connector (cavity 2). Q: Is there any voltage present? YES: Go To 3 NO: Replace the Seat Belt Tensioner Reducer. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. SEAT BELT SWITCH Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2928 Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Measure the resistance between ground and the (Z951) Seat Belt Switch circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2929 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Open DRIVER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2930 Driver Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z75) driver door ajar switch ground circuit - Open (G75) driver door ajar switch sense circuit - Open driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2931 DIAGNOSTIC TEST 1. OPEN DRIVER DOOR AJAR SWITCH Disconnect the Driver Door Latch connector. Connect a jumper wire between the (G75) Sense circuit and the (Z75) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z75) DRIVER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z75) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES:Go To 3 NO: Repair the (Z75) Driver Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2932 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G75) Driver Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G75) Driver Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Shorted to Ground DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2933 Driver Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G75) Driver door ajar switch sense circuit short to ground - Driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2934 DIAGNOSTIC TEST 1. DRIVER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Driver Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G75) Driver Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G75) Driver Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Open LEFT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2935 Left Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z79) left rear door ajar switch ground circuit - Open (G77) left rear door ajar switch sense circuit - Open left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2936 DIAGNOSTIC TEST 1. OPEN LEFT REAR DOOR AJAR SWITCH Disconnect the Left Rear Door Latch connector. Connect a jumper wire between the (G77) Sense circuit and the Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO:Go To 2 2. OPEN (Z79) LEFT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z79) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z79) Left Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2937 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G77) Left Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Shorted to Ground LEFT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2938 Left Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G77) Left rear door ajar switch sense circuit short to ground - Left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2939 DIAGNOSTIC TEST 1. LEFT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Left Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G77) Left Rear Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Open PASSENGER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2940 Passenger Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z74) passenger door ajar switch ground circuit - Open (G74) passenger door ajar switch sense circuit - Open passenger door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2941 DIAGNOSTIC TEST 1. OPEN PASSENGER DOOR AJAR SWITCH Disconnect the Passenger Door Latch connector. Connect a jumper wire between the (G74) Sense circuit and the (Z74) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z74) PASSENGER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z74) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z74) Passenger Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2942 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G74) Passenger Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G74) Passenger Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Shorted to Ground PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2943 Passenger Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G74) Passenger door ajar switch sense circuit short to ground - Passenger door ajar switch - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2944 1. PASSENGER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Passenger Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G74) Passenger Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G74) Passenger Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Open RIGHT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2945 Right Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z72) right rear door ajar switch ground circuit - Open (G76) right rear door ajar switch sense circuit - Open right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2946 DIAGNOSTIC TEST 1. OPEN RIGHT REAR DOOR AJAR SWITCH Disconnect the Right Rear Door Latch connector. Connect a jumper wire between the (G76) Sense circuit and the (Z72) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Right Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z72) RIGHT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z72) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z72) Right Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2947 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G76) Right Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Shorted to Ground RIGHT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2948 Right Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G76) Right rear door ajar switch sense circuit short to ground - Right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2949 DIAGNOSTIC TEST 1. RIGHT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Right Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Right Rear Door Ajar Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G76) Right Rear Door Ajar Switch Sense circuit and test for a short to ground. Q: Does the test light illuminate brightly? YES: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Average Fuel Economy Inaccurate or Wrong AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2950 - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. CMTC or EVIC Inoperative CMTC OR EVIC INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2951 CMTC Or EVIC Inoperative POSSIBLE CAUSES - (F21) Fused ignition switch output (run/start) circuit open - (Z13) Electronic overhead module ground circuit open - Electronic overhead module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2952 1. (F21) FUSED IGNITION RUN/START CIRCUIT OPEN NOTE: Diagnose and repair any MIC, FCM, PCM, or Communication DTCs before proceeding. Turn the ignition off. Disconnect the Electronic Overhead Module harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 0.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (Z13) ELECTRONIC OVERHEAD MODULE GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance between ground and the (Z13) Electronic Overhead Module Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z13) Electronic Overhead Module Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Compass Test Failure COMPASS TEST FAILURE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2953 WHEN MONITORED With the ignition on. SET CONDITION The Electronic Overhead Module (EOM) display reads "FAILED SELF TEST." POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Depress and hold the RESET and C/T buttons while turning the ignition on. NOTE: This test may also be performed using the DRBIII(R). Q: Does the EOM or DRBIII(R) display "FAILED SELF TEST"? YES: Replace the EOM. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Distance to Empty Inaccurate or Wrong DISTANCE TO EMPTY INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Elapsed Ignition On Time Inaccurate or Wrong ELAPSED IGNITION ON TIME INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2954 Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Temperature Display Inaccurate or Inoperative TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Electronic overhead module 1. AMBIENT TEMPERATURE SENSOR NOTE: - Diagnose and repair any FCM, EOM, PCM, or Communication DTCs before proceeding with this test. - The Ambient Temperature Sensor is hardwired to the FCM (Diesel), or to the PCM. Ambient temperature information is transmitted to the EOM via the PCI Bus. Turn the ignition off. Disconnect the Ambient Temperature Sensor harness connector. Measure the resistance of the Ambient Temperature Sensor using the following temperature/resistance values: 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.88 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms 50° C (122° F) Sensor Resistance = 3.33 - 3.88 Kilohms Q: Is the Ambient Temperature Sensor resistance measurement within the min/max specifications? YES: Go To 2 NO: Replace the Ambient Temperature Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. ELECTRONIC OVERHEAD MODULE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2955 Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Press and hold the C/T and Reset buttons. Turn the ignition on. NOTE: NOTE: The self test can also be performed using the DRBIII(R). Observe the EOM display at the conclusion of the self test. Q: Does the EOM display "Passed Self Test"? YES: Test Complete. NO: Replace and configure the EOM. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Trip Odometer Inaccurate or Wrong TRIP ODOMETER INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC VEHICLE INFORMATION CENTER NOTE: - Diagnose and repair any FIDEM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the OEM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. All Door Locks Inoperative ALL DOOR LOCKS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2956 All Door Locks Inoperative POSSIBLE CAUSES - DTC present - Fuse #22 open - (A941) Fuse B+ circuit open - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2957 Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock or Cluster related DTC's? YES: Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. FUSE #22 OPEN Test both sides of fuse #22 in the PDC. Q: Is there 12 volts on both sides of fuse #22? YES: Go To 3 NO: Replace the fuse if open and retry the system. If the fuse blows, locate and repair a short to the Instrument Cluster. The 12 volt supply to the fuse is a bus bar in the PDC. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. (A941) FUSED B+ CIRCUIT OPEN Turn the ignition off. Remove the instrument cluster. Measure the voltage between the (A941) Fused B+ circuit and ground (cavity 2 in the C1 connector to ground). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2958 Q: Is the voltage above 10.0 volts on the Fused B+ circuit? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Fused B+ circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Automatic (Rolling) Door Locks Inoperative AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Door ajar switch status incorrect - TPS or VSS DTC's - Auto door locks not enabled - Instrument cluster Diagnostic Test 1. CHECK THE DOOR AJAR SWITCH STATUS Ensure all doors are closed. With the DRBIII, enter "Electro/Mech Cluster" then "Input/Output" and observe all of the Door Ajar states. Q: Does the DRBIII display CLOSED for any door ajar state? YES: Select the appropriate Door Ajar Circuit Shorted: NO: Go To 2 2. ANY TPS OR VSS RELATED DTC'S With the DRBIII read "Engine" and "Anti-Lock Brakes" DTC's. Q: Does the DRBIII display any Throttle Position Sensor or Vehicle Speed Sensor related DTC's? YES: Diagnose and repair the DTC's. NO: Go To 3 3. ENABLE AUTO DOOR LOCKS With the DRBIII, enter "Electron/Mech Cluster" then "Miscellaneous" and observe the rolling door lock status. Q: Does the DRBIII display ROLLING DOOR LOCKS: ENABLED YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: With the DRBIII, enable the Auto Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2959 Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Cylinder Lock Switch Inoperative CYLINDER LOCK SWITCH INOPERATIVE Cylinder Lock Switch Inoperative POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2960 DTC PRESENT - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch mux circuit open - (G163) Cylinder lock switch mux wire short to ground - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Turn the ignition on. Measure the voltage between (G163) Cylinder Lock Switch Mux circuit and ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2961 Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2962 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Door Lock Inhibit Inoperative DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster Diagnostic Test 1. CHIME INOPERATIVE Turn the ignition off but leave the key in the ignition. Open the drivers door. Q: Does the chime sound? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Perform the test "KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE". See: Chime System/Key In Ignition and Drivers Door Open Chime Inoperative Driver Door Fails to Lock and Unlock DRIVER DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2963 Driver Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P1) Door unlock driver left front wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2964 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P1) Door Unlock Driver Left Front circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Driver Door lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2965 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Driver Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P1) DOOR UNLOCK DRIVER LEFT FRONT WIRE OPEN Measure the resistance of the (P1) Door Unlock Driver Left Front circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P1) Door Unlock Driver Left Front wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Fails to Lock & Unlock LEFT REAR DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2966 Left Rear Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P5) Door unlock driver left rear wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2967 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks to diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P5) Door Unlock Driver Left Rear circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the left doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2968 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Left Rear Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P5) DOOR UNLOCK DRIVER LEFT REAR WIRE OPEN Measure the resistance of the (P5) Door Unlock Driver Left Rear circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P5) Door Unlock Driver Left Rear wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Door Lock Motor Inoperative ONE DOOR LOCK MOTOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2969 POSSIBLE CAUSES - DTC's present - Door lock driver or door unlock driver circuit open - Door latch Diagnostic Test 1. CHECK DOOR LOCK MOTOR CIRCUIT With the DRBIII(R), read DTCs. If there are any door lock related DTC's, refer to symptom list for problems related to Power Door Locks and diagnose and repair the DTC's. Disconnect the inoperative Door Latch connector. Connect a 12 volt test light between the Door Lock Driver and the Door Unlock Driver circuits in the latch connector. NOTE: Graphic shows Passenger Latch - all others similar. Operate the door locks several time in the lock and unlock positions from a door lock switch and observe the test light. Q: Does the test light illuminate brightly when the locks are actuated in both directions? YES: Replace the Door latch. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the appropriate Door Lock Driver or Door Unlock Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Doors Fail to Lock and Unlock - Quad Cab RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2970 Right Doors Fail To Lock And Unlock - Quad Cab POSSIBLE CAUSES - DTC present - (P392) Door lock driver right doors wire open - (G778) Door unlock driver right doors wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2971 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (G778) Door Unlock Driver Right Doors circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P392) Door Lock Driver Right Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Right Doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2972 NO: Go To 3 3. (P392) DOOR LOCK DRIVER RIGHT DOORS WIRE OPEN Disconnect the Passenger Door Latch connector. Measure the resistance of the (P392) Door Lock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P392) Door Lock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G778) DOOR UNLOCK DRIVER RIGHT DOORS WIRE OPEN Measure the resistance of the (G778) Door Unlock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST-VER 1. NO: Repair the (G778) Door Unlock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test RKE Inoperative RKE INOPERATIVE POSSIBLE CAUSES - DTC present Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2973 - Transmitter not programmed - RKE transmitter - Remote keyless entry module Diagnostic Test 1. DTC PRESENT With the DRBIII(R), read DTCs. Attempt to operate the door locks with the RKE transmitter. Q: Does the DRBIII(R) display RKE FOB BATTERY LOW? YES: Refer to symptom RKE FOB BATTERY LOW in this category. NO: Go To 2 2. 9001 TESTER AVAILABLE Q: Do you have access to the Miller Special Tool "9001 RF DETECTOR"? NO: Go To 3 YES: Go To 5 3. TRANSMITTER NOT PROGRAMMED Turn the ignition on. Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarmed Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Try the door locks using the Transmitter. Q: Does the RKE System operate properly? YES: Repair complete. Check with the customer to see if the other transmitters) are operating properly. They may have to be programmed also. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. SUBSTITUTE A KNOWN GOOD TRANSMITTER Secure a known good transmitter. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2974 Lock and Unlock the vehicle using the transmitter. Q: Does the RKE System operate properly? YES: Replace the original transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. TEST TRANSMITTER WITH TESTER Using the 9001 RF Detector, follow the instructions on the back of the tester and test the transmitter several times. Q: Does the signal strength measure "STRONG"? YES: Go To 6. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. PROGRAM RKE TRANSMITTER WITH THE DRBIII(R) Turn the ignition on Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarm Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, then PROGRAM New Fob. Follow the instructions on the screen. Exit PROGRAM RKE. Activate the Door Locks using the RKE Transmitter. NOTE: When repairs are complete, ensure all transmitters used with the vehicle have been programmed. Q: Did the door locks respond properly to the RKE transmitter commands? YES: Repair complete. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Alarm Trips On Its Own ALARM TRIPS ON ITS OWN Diagnostic Test 1. LAST VTSS CAUSE With the DRBIII(R) in Inputs/Outputs, read the Last VTSS Cause state. Q: Were there any causes displayed? YES: Check for a possible intermittent condition with the circuit indicated by the DRBIII(R). Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: The condition that caused this symptom is currently not present. Inspect the related wiring harness for a possible intermittent condition. Look for any chafed, pierced, pinched or partially broken wires. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Cylinder Lock Switch INOP CYLINDER LOCK SWITCH INOP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2975 Cylinder Lock Switch Inop POSSIBLE CAUSES - DTC present - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch MUX circuit open - (G163) Cylinder lock switch MUX wire short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2976 - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Measure the voltage between (G163) Cylinder Lock Switch MUX circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2977 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform Body Verification Test Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2978 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Does Not Trip VTSS DRIVER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the DRIVER DOOR AJAR SW status. Open the driver door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom DRIVER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the driver's door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the driver door lock. Attempt to trip the VTSS by opening the drivers door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2979 Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Headlamps Fail to Flash When Alarm Is Tripped HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster 1. CHECK FCM DTCS AND HIGH BEAM HEADLAMP OPERATION Attempt to operate the exterior lamps with the headlamp switch. With the DRBIII(R), read FCM DTCs. Q: Were there any problems found? YES: Refer to symptom list for problems related to Exterior Lighting. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Horn Fails to Sound When Alarm Is Tripped HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to the Ignition, Power, Accessory category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 2 2. HORN CIRCUIT DIAGNOSTICS Q: Does the horn operate from the horn button? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Refer to symptom Horns Inoperative in the Ignition, Power, Accessory category. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Left Rear Door Does Not Trip VTSS (4 Door) LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2980 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Left Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom LEFT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the left rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the left rear door lock. Attempt to trip the VTSS by opening the left rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Does Not Trip VTSS PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the passenger door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom PASSENGER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the passenger door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the passenger door lock. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2981 Attempt to trip the VTSS by opening the passenger door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Does Not Trip VTSS (4 Door) RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Right Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom RIGHT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the right rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the right rear door lock. Attempt to trip the VTSS by opening the right rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2982 NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test VTSS Will Not Arm Properly VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster 1. ATTEMPT TO ENABLE THE VTSS Turn the ignition Off to the lock position. Disconnect the battery negative cable wait 5 seconds then reconnect battery cable. Turn the ignition to the On position for 10 seconds, then back Off to the lock position and remove key. Close all doors. Using the key, lock the vehicle with the Driver Door Cylinder Lock Switch and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Go To 2 NO: Go To 3 2. VTSS NOT ENABLED Unlock the vehicle to disarm the VTSS. Ensure all doors are closed. Using the RKE key fob, lock the vehicle and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Test Complete. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. USE DRB TO COMMUNICATE WITH THE SKIM With the DRBIII(R), attempt to communicate with the SKIM. Q: Does the DRBIII(R) communicate with the SKIM? YES: Go To 4 NO: Refer to communication category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 4. DTC OR VTSS INHIBITORS Ensure the doors are closed. With the DRBIII(R), read the active DTC's and the ajar switch states. Q: Does the DRBIII(R) display any closed switches or related DTC's? YES: Refer to the Symptom List and diagnose the appropriate symptom in the DOOR AJAR or related category. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 5 5. CYLINDER LOCK SWITCH CIRCUIT OPEN Turn the ignition on. With the DRBIII(R), read the Driver Cylinder Lock Switch MUX volts while turning the key in the driver door lock cylinder. Q: Did the MUX voltage change from approximately 5.0 volts to 4.0 for lock and 2.4 for unlock? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2983 YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. INSTRUMENT CLUSTER CYLINDER LOCK SWITCH VOLTAGE LOW Disconnect the Cylinder Lock Switch connector. Measure the voltage between Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 7 NO: Go To 8 7. CYLINDER LOCK SWITCH GROUND OPEN Disconnect the Cylinder Lock Switch connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Ground circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 8. CYLINDER LOCK SWITCH MUX OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 2984 Disconnect the Cylinder Lock Switch connector. Disconnect the Instrument Cluster C2 connector. Measure the resistance of the Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Cylinder Lock Switch Mux circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: Customer Interest Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2993 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 2994 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Engine Control Module: All Technical Service Bulletins Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3000 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3001 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3006 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3007 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3008 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3009 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3010 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3011 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3012 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3013 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3014 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3015 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3020 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3021 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3022 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs Engine Control Module: All Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3028 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3029 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3030 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3031 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3032 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3033 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3034 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3035 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3036 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3037 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3042 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3043 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3044 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3045 Engine Control Module: Locations Right Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3046 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Module-Engine Control C1 Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3049 Module-Engine Control C1 Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3050 Module-Engine Control C1 Part 3 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3051 Module-Engine Control C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3052 Module-Powertrain Control C1 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3053 Module-Powertrain Control C2 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3054 Module-Powertrain Control C3 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3055 Module-Powertrain Control C4 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3058 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3059 Engine Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3060 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3061 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3062 Engine Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3063 Engine Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3064 Engine Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3065 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3066 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3067 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM > Page 3068 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming Engine Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 3071 Engine Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 3072 Engine Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 3073 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 3074 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 3080 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3081 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3082 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3083 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 3087 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 3093 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3094 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3095 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3096 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3100 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3101 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3102 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3103 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3104 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3108 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3109 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3110 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3111 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3116 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3117 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3118 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3119 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3120 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 3125 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3126 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3127 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3131 Sensor-Intake Air Temperature (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3132 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3133 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3134 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counter-clockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3138 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3139 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3140 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3141 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3145 Sensor-Map (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3146 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3147 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3148 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counter-clockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3149 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3158 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3159 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3160 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3161 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3167 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3168 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3169 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3170 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3173 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3174 Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3175 Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3176 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (3.7L/5.7L) Sensor-Oxygen-Left Rear (3.7L/5.7L LD) Sensor-Oxygen-Left Rear (5.7L HD) Sensor-Oxygen-Right Front (3.7L/5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3177 Sensor-Oxygen-Right Rear (3.7L/5.7L LD) Sensor-Oxygen-Right Rear (5.7L HD) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3178 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3179 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3180 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3184 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3185 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3186 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3190 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3197 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CONVERTER - CATALYTIC DESCRIPTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter. OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3205 Catalytic Converter: Service and Repair CONVERTER - CATALYTIC 5.7L ENGINE 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove clamps and nuts (4). 5. Remove catalytic converter to exhaust manifold bolts (2) and nuts (1). 6. Remove catalytic converter assembly (3). INSTALLATION 5.7L ENGINE 1. Install catalytic converter to exhaust clamp (4) on catalytic converter (3) and position into exhaust pipe (5). 2. Make sure the alignment tang on catalytic converter (3) is fully seated in the notch on the exhaust pipe (5). 3. Install catalytic converter to exhaust manifold bolts (2) and nuts (1). 4. Tighten catalytic converter to exhaust manifold bolts (2) to 31 Nm (23 ft. lbs.). 5. Tighten catalytic converter to exhaust pipe clamp nuts (4) to 52.2 Nm (40 ft. lbs.) torque. 6. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Canister Purge Solenoid: Component Locations The duty cycle EVAP canister purge solenoid is located in the engine compartment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3211 Canister Purge Solenoid: Connector Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3212 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3213 Solenoid-EVAP/Purge (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3214 Canister Purge Solenoid: Description and Operation The duty cycle EVAP canister purge solenoid is located in the engine compartment. It is attached to the side of the Power Distribution Center (PDC). The Powertrain Control Module (PCM) operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes. The PCM adjusts solenoid pulse width based on engine operating condition. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3215 Canister Purge Solenoid: Service and Repair REMOVAL The duty cycle EVAP canister purge solenoid (3) is located in the engine compartment. It is attached to the side of the Power Distribution Center (PDC). 1. Disconnect electrical wiring connector at solenoid. 2. Disconnect vacuum harness (2) at solenoid. 3. Remove solenoid from mounting bracket. INSTALLATION 1. Install solenoid assembly to mounting bracket. 2. Connect vacuum harness. 3. Connect electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3224 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3225 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3231 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3232 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations EVAP canisters (5) are located near the front of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3236 Evaporative Emission Control Canister: Description and Operation Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3237 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. The EVAP canisters are filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canisters are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canisters. Fuel vapors are temporarily held in the canisters until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canisters to be purged at predetermined times and at certain engine operating conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3238 Evaporative Emission Control Canister: Service and Repair REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3239 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Type 1 Canisters Use the following procedure for vertically mounted canisters. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3240 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). Remove necessary skid plates. 3. Remove fuel tubes/lines at each EVAP canister. Note location of tubes/lines before removal for easier installation. 4. Remove lower support bracket (4). 5. Remove mounting nuts (1) at top of each canister. 6. Remove each canister from upper support bracket. Type 2 Canisters Use the following procedure for horizontally mounted canisters. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). Remove necessary skid plates. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3241 3. Remove fuel tubes/lines (1) at each EVAP canister. Note location of tubes/lines before removal for easier installation. Remove bolts (6). 4. Remove nut (1) and remove NVLD filter (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3242 5. Remove nuts (4) and remove NVLD filter support bracket (2). Remove upper canister. 6. Remove nuts (5) and remove lower canister (6). Slip lower canister pins (7) from rubber grommets. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3243 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3244 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Type 1 Canisters Use the following procedure for vertically mounted canisters. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3245 1. Place each canister (5) and (6) into upper support bracket and install nuts. Refer to Torque Specifications. 2. Install lower support bracket (4). Refer to Torque Specifications. 3. Carefully install vapor/vacuum lines. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD Pump, LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. If necessary, install skid plate(s). Type 2 Canisters Use the following procedure for horizontally mounted canisters. 1. Slip lower canister pins (7) into rubber grommets. Install lower canister (6) and nuts (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3246 2. Install upper canister (1). Install NVLD filter support bracket (2) and install nuts (4). 3. Install NVLD filter (2) and nut (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3247 4. Carefully install vapor/vacuum lines, and fuel tubes/lines (1) to each EVAP canister. Install bolts (6). 5. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD Pump, LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 6. If necessary, install skid plate(s). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3256 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3257 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3263 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3264 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams Assembly - Natural Vacuum Leak Detection (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump Leak Detection Pump: Locations Leak Detection Pump The Leak Detection Pump (LDP) (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump > Page 3272 Leak Detection Pump: Locations Natural Vac Leak Detection Equipped With Horizontally Mounted EVAP Canisters The NVLD pump (4) is attached to the EVAP canister. Equipped With Vertically Mounted EVAP Canisters Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump > Page 3273 The NVLD pump (4) is located at the front of fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump Leak Detection Pump: Description and Operation Leak Detection Pump Vehicles equipped with JTEC engine control modules use a leak detection pump. Vehicles equipped with NGC engine control modules use an NVLD pump. Refer to Natural Vacuum - Leak Detection (NVLD) for additional information. The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require onboard testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister: The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5" H2O (1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. LDP AT REST (NOT POWERED) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3276 When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. DIAPHRAGM DOWNWARD MOVEMENT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3277 Based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PCM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve. The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION Action : During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040 inches LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020 inches LEAK DETECTED Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3278 - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3279 Leak Detection Pump: Description and Operation Natural Vac Leak Detection Vehicles equipped with an NGC Powertrain Control Module (PCM) use a Natural Vacuum Leak Detection (NVLD) pump and system. Vehicles equipped with a JTEC PCM use an LDP (Leak Detection Pump). Refer to Leak Detection Pump (LDP) for additional information. The NVLD pump is located in the same area as the leak detection pump. Refer to NVLD Removal/Installation for additional information. The Natural Vacuum Leak Detection (NVLD) system is the new generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller (NGC). This new system replaces the leak detection pump as the method of evaporative system leak detection. This is to detect a leak equivalent to a 0.020 inches (0.5 mm) hole. This system has the capability to detect holes of this size very dependably. The basic leak detection theory employed with NVLD is the "Gas Law". This is to say that the pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel will only see this effect if it is indeed sealed. Even small leaks will allow the pressure in the vessel to come to equilibrium with the ambient pressure. In addition to the detection of very small leaks, this system has the capability of detecting medium as well as large evaporative system leaks. A vent valve seals the canister vent during engine off conditions. If the vapor system has a leak of less than the failure threshold, the evaporative system will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak determination by this diagnostic. When the vacuum in the system exceeds about 1 inches H2O (0.25 KPA), a vacuum switch closes. The switch closure sends a signal to the NGC. The NGC, via appropriate logic strategies, utilizes the switch signal, or lack thereof, to make a determination of whether a leak is present. The NVLD device is designed with a normally open vacuum switch, a normally closed solenoid, and a seal, which is actuated by both the solenoid and a diaphragm. The NVLD is located on the atmospheric vent side of the canister. The NVLD assembly may be mounted on top of the canister outlet, or in-line between the canister and atmospheric vent filter. The normally open vacuum switch will close with about 1 inches H2O (0.25 KPA) vacuum in the evaporative system. The diaphragm actuates the switch. This is above the opening point of the fuel inlet check valve in the fill tube so cap off leaks can be detected. Submerged fill systems must have recirculation lines that do not have the in-line normally closed check valve that protects the system from failed nozzle liquid ingestion, in order to detect cap off conditions. The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system during the engine off condition. If vacuum in the evaporative system exceeds 3 inches to 6 inches H2O (0.75 to 1.5 KPA), the valve will be pulled off the seat, opening the seal. This will protect the system from excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative. The solenoid actuates the valve to unseal the canister vent while the engine is running. It also will be used to close the vent during the medium and large leak tests and during the purge flow check. This solenoid requires an initial 1.5 amps of current to pull the valve open, but after 100 milli-seconds, will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle. Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system. The device will "blow off' at about 0.5 inches H2O (0.12 KPA) pressure to permit the venting of vapors during refueling. An added benefit to this is that it will also allow the tank to "breathe" during increasing temperatures, thus limiting the pressure in the tank to this low level. This is beneficial because the induced vacuum during a subsequent declining temperature will achieve the switch closed (pass threshold) sooner than if the tank had to decay from a built up pressure. The device itself has 3 wires: Switch sense, solenoid driver and ground. It also includes a resistor to protect the switch from a short to battery or a short to ground. The NGC utilizes a high-side driver to energize and duty-cycle the solenoid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump Leak Detection Pump: Service and Repair Leak Detection Pump REMOVAL The Leak Detection Pump (LDP) (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. This is located near the front of the fuel tank. The LDP and LDP filter are replaced (serviced) as one unit. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Carefully remove hose at LDP filter. 4. Remove LDP filter mounting bolt and remove from vehicle. 5. Carefully remove vapor/vacuum lines at LDP. 6. Disconnect electrical connector at LDR 7. Remove LDP mounting bolt and remove LDP from vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3282 The LDP (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. The LDP and LDP filter are replaced (serviced) as one unit. 1. Install LDP to mounting bracket. Refer to Torque Specifications. 2. Install LDP filter to mounting bracket. Refer to Torque Specifications. 3. Carefully install vapor/vacuum lines to LDP, and install hose to LDP filter. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. Connect electrical connector to LDP. 5. If necessary, install skid plate(s). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3283 Leak Detection Pump: Service and Repair Natural Vac Leak Detection Pump Equipped With Horizontally Mounted EVAP Canisters REMOVAL The NVLD pump (4) is attached to the EVAP canister. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Disconnect electrical connector at NVLD assembly. 4. Carefully disconnect vapor lines from NVLD assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3284 5. Lift tab on NVLD assembly and twist assembly counterclockwise. 6. Pull NVLD pump out to remove from EVAP canister. 7. Remove O-ring from EVAP canister. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3285 INSTALLATION The NVLD pump (4) is attached to the EVAP canister. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3286 1. Install new O-ring to EVAP canister. 2. Align NVLD assembly into EVAP canister. 3. Rotate NVLD assembly until alignment tab drops into slot. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3287 4. Connect electrical connector to NVLD assembly. 5. Carefully install vapor/vacuum lines to NVLD pump. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the NVLD pump, filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 6. If necessary, install skid plate(s). Equipped With Vertically Mounted EVAP Canisters REMOVAL The NVLD pump (4) is located at the front of fuel tank. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Disconnect electrical connector at pump. 4. Carefully remove vapor/vacuum hoses at pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3288 5. The NVLD pump snaps into the EVAP canister. Press on release tab (2) while rotating pump from canister. INSTALLATION The NVLD pump (4) is located at the front of fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3289 1. Snap NVLD pump (1) to EVAP canister until tab (2) engages. 2. Connect electrical connector to NVLD pump. 3. Carefully install vapor/vacuum lines to NVLD pump. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the NVLD pump, filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. If equipped, install skid plate(s). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation The ORVR (On-Board Refueling Vapor Recovery) system consists of a unique fuel tank, flow management valve, fluid control valve, one-way check valve and vapor canister. The ORVR (On-Board Refueling Vapor Recovery) system is used to remove excess fuel tank vapors. This is done while the vehicle is being refueled. Fuel flowing into the fuel filler tube (approx. 1 inches I.D.) creates an aspiration effect drawing air into the fuel fill tube. During refueling, the fuel tank is vented to the EVAP canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the EVAP canister, the vehicle's computer controlled purge system draws vapor out of the canister for the engine to burn. The vapor flow is metered by the purge solenoid so that there is no, or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fuel fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve and on to the vapor canister. Vapor is absorbed in the EVAP canister until vapor flow in the lines stops. This stoppage occurs following fuel shut-off, or by having the fuel level in the tank rise high enough to close the control valve. This control valve contains a float that rises to seal the large diameter vent path to the EVAP canister. At this point in the refueling process, fuel tank pressure increases, the check valve closes (preventing liquid fuel from spiting back at the operator), and fuel then rises up the fuel filler tube to shut off the dispensing nozzle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations EGR Control Solenoid: Component Locations The electronic EGR valve and solenoid assembly (2) is attached to the front of the right cylinder head. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations > Page 3298 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3299 EGR Control Solenoid: Service and Repair REMOVAL The electronic EGR valve and solenoid assembly (3) is attached to the front of the right cylinder head (1). An exhaust gas routing tube connects the EGR valve to the intake manifold. 1. Disconnect electrical connector (1) from EGR solenoid (2). 2. Remove two bolts (3) connecting EGR tube (4) to valve assembly. 3. Remove gasket located between EGR tube flange and EGR valve assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3300 4. Remove two mounting bolts (2). 5. Separate valve assembly (3) from cylinder head (1). 6. Remove and discard metal gasket located between cylinder head and valve assembly. INSTALLATION 1. Position a new metal gasket between cylinder head (1) and valve assembly (3). 2. Install two mounting bolts (2) and tighten. Refer to Torque Specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3301 3. Clean EGR tube where it joins EGR valve. 4. Position new gasket between EGR tube flange and EGR valve assembly. 5. Install two bolts (3) connecting EGR tube (4) to valve assembly (2). Tighten bolts. Refer to Torque Specifications. 6. Connect electrical connector (1) to EGR solenoid (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations EGR Valve: Locations The electronic EGR valve and solenoid assembly (2) is attached to the front of the right cylinder head. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3305 Assembly - Exhaust Gas Recirculation Valve (4.7L/5.7L LD) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3306 EGR Valve: Description and Operation The electronic EGR valve and solenoid assembly (2) is attached to the front of the right cylinder head. An exhaust gas routing tube (4) connects the EGR valve to the intake manifold. Exhaust gas recirculation flow is determined by the Powertrain Control Module (PCM) and is controlled by an electronic EGR valve assembly. For a given set of conditions, the PCM knows the ideal exhaust gas recirculation flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The PCM adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct position. The electronic EGR valve assembly consists of a pintle, valve seat, and housing which contains and regulates exhaust gas flow. An armature, return spring, and solenoid coil provide the operating force to regulate exhaust gas flow by changing the pintle position. The solenoid coil assembly is wired in parallel with a diode that connects two internal connectors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3307 EGR Valve: Service and Repair REMOVAL The electronic EGR valve and solenoid assembly (3) is attached to the front of the right cylinder head (1). An exhaust gas routing tube connects the EGR valve to the intake manifold. 1. Disconnect electrical connector (1) from EGR solenoid (2). 2. Remove two bolts (3) connecting EGR tube (4) to valve assembly. 3. Remove gasket located between EGR tube flange and EGR valve assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3308 4. Remove two mounting bolts (2). 5. Separate valve assembly (3) from cylinder head (1). 6. Remove and discard metal gasket located between cylinder head and valve assembly. INSTALLATION 1. Position a new metal gasket between cylinder head (1) and valve assembly (3). 2. Install two mounting bolts (2) and tighten. Refer to Torque Specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3309 3. Clean EGR tube where it joins EGR valve. 4. Position new gasket between EGR tube flange and EGR valve assembly. 5. Install two bolts (3) connecting EGR tube (4) to valve assembly (2). Tighten bolts. Refer to Torque Specifications. 6. Connect electrical connector (1) to EGR solenoid (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations This engine is equipped with a closed crankcase ventilation system and a Positive Crankcase Ventilation (PCV) valve. This system consists of: Fig.12 Location 5.7L PCV Value Fig.13 5.7L PCV Value - a PCV valve mounted into the top of the intake manifold, located to the right / rear of the throttle body. The PCV valve is sealed to the intake manifold with 2 O-rings. - passages in the intake manifold. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3314 - tubes and hoses to connect the system components. Fig.15 Typical Closed Crankcase Ventilation System The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase pressure and meters blow by gases to the intake system, reducing engine sludge formation. Fig.16 Engine Off Or Engine Backfire - No Vapor Flow The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Fig.17 High Intake Manifold Vacuum - Minimal Vapor Flow Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3315 During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Fig.18 Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3316 Positive Crankcase Ventilation Valve: Description and Operation The 5.7L V-8 engine is equipped with a closed crankcase ventilation system and a Positive Crankcase Ventilation (PCV) valve (4). This system consists of: - a PCV valve mounted into the top of the intake manifold, located to the right I rear of the throttle body. The PCV valve (1) is sealed to the intake manifold with 2 O-rings (2). - passages in the intake manifold. - tubes and hoses to connect the system components. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3317 A typical enclosed crankcase ventilation system is shown in the graphic. The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve (4) and into a passage in the intake manifold. The PCV system manages crankcase pressure and meters blow by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3318 During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3319 Positive Crankcase Ventilation Valve: Service and Repair REMOVAL The PCV valve (4) is mounted into the top of the intake manifold (1). This is located to the right I rear of the throttle body (2). 1. The PCV valve is sealed to the intake manifold with 2 O-rings (2). 2. Remove PCV valve by rotating counter-clockwise 90 degrees until locating tabs (3) have been freed. After tabs have cleared, pull valve straight up from intake manifold. 3. After valve is removed, check condition of 2 valve O-rings (2). INSTALLATION 1. Clean out intake manifold opening. 2. Check condition of 2 O-rings on PCV valve. 3. Apply engine oil to 2 O-rings. 4. Place PCV valve into intake manifold and rotate 90 degrees clockwise for installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3324 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3325 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3332 Idle Speed: Description and Operation A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair REMOVAL The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). The accelerator pedal is serviced as a complete assembly including the bracket. The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (2).This plastic retainer snaps into the top of the accelerator pedal arm. 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of accelerator pedal arm. Plastic cable retainer (clip) snaps into pedal arm. 2. Remove 2 accelerator pedal mounting bracket nuts. Remove accelerator pedal assembly. INSTALLATION 1. Place accelerator pedal assembly over 2 studs. 2. Install and tighten 2 mounting nuts. Refer to Torque Specifications. 3. Slide throttle cable into opening slot in top of pedal arm. 4. Push plastic cable retainer (clip) into accelerator pedal arm opening until it snaps into place. 5. Before starting engine, operate accelerator pedal to check for any binding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 3340 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3341 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3342 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3343 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3348 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips(5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3349 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Selection ...................................................................................................................................... ................................... 89 Octane, (R+M)/2 Method .............................................................................................................................................. Mid-Grade preferred (87 Octane acceptable) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Certain models are equipped with a 1/4 turn cap. The loss of any fuel or vapor out of fuel filler tube is prevented by the use of a pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If equipped with a Leak Detection Pump (LDP), or NVLD system, the cap must be tightened securely. If cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 3356 Fuel Filler Cap: Service and Repair REMOVAL/INSTALLATION If replacement of the 1/4 turn fuel tank filler tube cap is necessary, it must be replaced with an identical cap to be sure of correct system operation. CAUTION: Remove the fuel tank filler tube cap to relieve fuel tank pressure. The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Information not supplied by manufacturer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3364 Fuel Injector: Diagrams Injector-Fuel-No.1 (NGC) Injector-Fuel-No.2 (NGC) Injector-Fuel-No.3 (NGC) Injector-Fuel-No.4 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3365 Injector-Fuel-No.5 (NGC) Injector-Fuel-No.6 (NGC) Injector-Fuel-No.7 (NGC) Injector-Fuel-No.8 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3366 Fuel Injector: Description and Operation An individual fuel injector (1) is used for each individual cylinder. The top (fuel entry) end of the injector (1) is attached into an opening on the fuel rail. The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. PCM OUTPUT The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3367 Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shut-down the 12 volt power source to the fuel injectors if the PCM senses the ignition is on, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds. The PCM determines injector on-time (pulse width) based on various inputs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3368 Fuel Injector: Service and Repair REMOVAL 1. Remove fuel rail. 2. Disconnect clip(s) that retain fuel injector(s) to fuel rail (2). INSTALLATION 1. Install fuel injector(s) into fuel rail assembly and install retaining clip(s). 2. If same injector(s) is being reinstalled, install new O-ring(s). 3. Apply a small amount of clean engine oil to each injector O-ring. This will aid in installation. 4. Install fuel rail. 5. Start engine and check for fuel leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information. CAUTION: - Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. - The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. STANDARD PROCEDURE - QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. DISCONNECTING WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. CAUTION: Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3372 5. The push-button is attached to two internal latches (1).To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN. 6. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 7. Disconnect negative battery cable from battery. 8. Clean fitting of any foreign material before disassembly. 9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3373 10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection. 11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3374 12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. 13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab. 14. Raise pull tab until it separates from quick-connect fitting. 15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1).The tabs are supplied for disconnecting quickconnect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quickconnect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. 16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. a. To release fuel system component from quickconnect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3375 17. Latch Clips - Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together. 18. Pry up on latch clip with a screwdriver (3). 19. Slide latch clip toward fuel rail while lifting with screwdriver. 20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1).Use tool to release locking fingers in end of line. 21. With special tool still inserted, pull fuel line from fuel rail. 22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 23. Disconnect quick-connect fitting from fuel system component being serviced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3376 24. Latch Clips -Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together. 25. Type 2: Separate and unlatch 2 small arms (1) on end of clip and swing away from fuel line. 26. Slide latch clip toward fuel rail while lifting with screwdriver. 27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1).Use tool to release locking fingers in end of line. 28. With special tool still inserted, pull fuel line from fuel rail. 29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 30. Disconnect quick-connect fitting from fuel system component being serviced. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Fuel Filter/Pressure Regulator Fuel Pressure Regulator: Locations Fuel Filter/Pressure Regulator A combination of fuel filter and fuel pressure regulator (3) is located on the top of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Fuel Filter/Pressure Regulator > Page 3381 Fuel Pressure Regulator: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3382 Fuel Pressure Regulator: Description and Operation A combination fuel filter and fuel pressure regulator (3) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the Powertrain Control Module (PCM). The regulator is calibrated to maintain fuel system operating pressure of approximately 58 ± 2 psi at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. Refer to Fuel Pump Description and Operation for more information. If fuel pressure at the pressure regulator exceeds approximately 60 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3387 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3388 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3404 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3414 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3415 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 3419 Fuel Pump Pickup Filter: Service and Repair REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs (2) at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation The fuel injector rail is used to mount the fuel injectors to the engine. High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or joints. Do not attempt to separate the rail halves at these connecting hose or joints. Due to the design of the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose or joint. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose or joint. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3423 Fuel Rail: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED. CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube. Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube. 1. Remove fuel tank filler tube cap. 2. Perform Fuel System Pressure Release Procedure. 3. Remove negative battery cable at battery. 4. Remove flex tube (air cleaner housing to engine). 5. Remove air resonator box at throttle body. 6. Disconnect all spark plug cables from all spark plugs and ignition coils. Do not remove cables from cable routing tray. Note original cable positions while removing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3424 7. Remove spark plug cable tray from engine by releasing 4 retaining clips. Remove tray and cables from engine as an assembly. 8. Disconnect electrical connectors at all 8 ignition coils. Refer to Ignition Coil Removal/Installation. 9. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. 10. Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal. 11. Disconnect electrical connectors at all throttle body sensors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3425 12. Remove 4 fuel rail mounting bolts (2) and holdown clamps (3). 13. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes. Repeat this procedure (left/right) until all injectors have cleared machined holes. 14. Remove fuel rail (with injectors attached) from engine. 15. If fuel injectors are to be removed. INSTALLATION 1. If fuel injectors are to be installed. 2. Clean out fuel injector machined bores in intake manifold. 3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation. 4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold. 5. Guide each injector into intake manifold. Be careful not to tear injector O-rings. 6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down until injectors have bottomed on shoulders. 7. Install 4 fuel rail holdown clamps and 4 mounting bolts. 8. Position spark plug cable tray and cable assembly to intake manifold. Snap 4 cable tray retaining clips into intake manifold. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3426 9. Install all cables to spark plugs and ignition coils. 10. Connect electrical connector to throttle body. 11. Install electrical connectors to all 8 ignition coils. 12. Connect electrical connector to throttle body. 13. Connect electrical connectors at all fuel injectors. To install connector, refer to. Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. 14. Connect fuel line latch clip and fuel line to fuel rail. 15. Install air resonator to throttle body (2 bolts). 16. Install flexible air duct to air box. 17. Connect battery cable to battery. 18. Start engine and check for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3436 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3437 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3443 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3444 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 3449 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3472 Fuel Gauge Sender: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3473 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3482 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3483 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3489 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3490 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3494 Module-Fuel Pump Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3495 Fuel Tank Unit: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE FUEL PUMP MODULE, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. 1. Drain and remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inches drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counter-clockwise to remove lockring (5). 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. INSTALLATION 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inches drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 3499 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL The IAC motor is not serviceable on the 5.7L V-8 engine. INSTALLATION The IAC motor is not serviceable on the 5.7L V-8 engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 3505 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3506 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3507 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3508 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3535 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3536 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output Main Relay (Computer/Fuel System): Description and Operation PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > PCM Output > Page 3542 Main Relay (Computer/Fuel System): Description and Operation ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3543 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3544 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3545 Main Relay (Computer/Fuel System): Service and Repair REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 3551 Left Front Facia And Battery Tray Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3552 Sensor-Accelerator Pedal Position (5.7L ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3553 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3554 Accelerator Pedal Position Sensor: Service and Repair CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. REMOVAL 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3558 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 14-003-10 > Feb > 10 > Engine Controls ETC Lamp ON/DTC's P2110/P2118 Throttle Body: Customer Interest Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 14-003-10 > Feb > 10 > Engine Controls ETC Lamp ON/DTC's P2110/P2118 > Page 3567 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 14-003-10 > Feb > 10 > Engine Controls ETC Lamp ON/DTC's P2110/P2118 > Page 3568 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 Throttle Body: All Technical Service Bulletins Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3574 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3575 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3576 Throttle Body (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3577 Throttle Body: Description and Operation The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. 5.7L V-8 Engine: The throttle body on the 5.7L engine is an electrically controlled unit. A mechanical cable is not used to connect the throttle body to the accelerator pedal . The Accelerator Pedal Position Sensor (APPS) along with inputs from other sensors sets the throttle blade to pre-determined positions. Except 5.7L V-8 Engine: Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3578 Throttle Body: Service and Repair CAUTION: Do not use spray (carb) cleaners on any part of the throttle body. Do not apply silicone lubricants to any part of the throttle body. REMOVAL 1. Remove air duct and air resonator box at throttle body. 2. Disconnect electrical connector (2) at throttle body. 3. Remove 4 throttle body mounting bolts (4). 4. Remove throttle body from intake manifold. 5. Check condition of throttle body O-ring (2). 6. If the throttle body has been changed, the following procedure must be performed: a. Disconnect negative battery cable from battery. Leave cable disconnected for approximately 90 seconds. b. Reconnect cable to battery. c. Turn ignition switch ON, but do not crank engine. d. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn throttle body electrical parameters. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3579 1. Clean and check condition of throttle body-to-intake manifold O-ring (2). 2. Clean mating surfaces of throttle body and intake manifold. 3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins. 4. Install 4 mounting bolts. 5. Install electrical connector. 6. Install air plenum. 7. If the throttle body has been changed, the following procedure must be performed: a. Disconnect negative battery cable from battery. Leave cable disconnected for approximately 90 seconds. b. Reconnect cable to battery. c. Turn ignition switch ON, but do not crank engine. d. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn throttle body electrical parameters. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair REMOVAL The Throttle Control Cable on the 5.7L V-8 engine connects the accelerator pedal to the Accelerator Pedal Position Sensor (APPS). A separate mechanical cable is not routed to the throttle body. CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal, cables or APPS. 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm. The plastic cable retainer snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. Remove APPS. Refer to Accelerator Pedal Position Sensor (APPS) Removal/Installation. 4. From inside vehicle, remove cable clip. 5. Remove cable housing from dash panel and pull cable into engine compartment. 6. Remove cable housing at APPS bracket by pressing on release tab with a small screwdriver. To prevent cable housing breakage, press on tab only enough to release cable from APPS bracket. INSTALLATION 1. Attach cable to Accelerator Pedal Position Sensor (APPS). Refer to APPS Removal / Installation. 2. Push cable housing into rubber grommet and through opening in dash panel. 3. From inside vehicle, install clip holding cable to dashpanel. 4. From inside vehicle, slide throttle cable core wire into opening in top of pedal arm. 5. Push cable retainer (clip) into pedal arm opening until it snaps in place. 6. Before starting engine, operate accelerator pedal to check for any binding. 7. If necessary, use DRB III(R) Scan Tool to erase any APPS Diagnostic Trouble Codes (DTC's) from PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3586 Throttle Position Sensor: Service and Repair REMOVAL The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3592 5.7L The 5.7L engine (345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3593 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. 1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER) 3 CORRESPONDING SPARK PLUG NUMBER Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3601 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3602 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3603 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3604 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3609 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3610 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3611 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3612 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3613 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3617 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3618 Ignition Cable: Service and Repair REMOVAL Spark plug cables on the 5.7L engine are paired on cylinders 1/6, 2/3, 4/7 and 5/8. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. The cable retention clips must also be securely locked. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. If cable tray removal is necessary, release the 4 tray-to-manifold retention clips. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil: Diagrams Coil - Ignition-No.1 (5.7L) Coil - Ignition-No.2 (5.7L) Coil - Ignition-No.3 (5.7L) Coil - Ignition-No.4 (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3622 Coil - Ignition-No.5 (5.7L) Coil - Ignition-No.6 (5.7L) Coil - Ignition-No.7 (5.7L) Coil - Ignition-No.8 (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Ignition Coil Ignition Coil: Description and Operation Ignition Coil The 5.7L V-8 engine uses 8 dedicated, and individually fired coil (1) for each pair of spark plugs. Each coil (5) is mounted directly to the top of each spark plug. Each coil is bolted (6) to the valve cover. The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. A "wasted spark" system is used on the 5.7L engine combining paired, or dual-firing coils, and 2 spark plugs per cylinder. The coils and spark plugs are connected with paired, secondary high-voltage cables. Each cylinder is equipped with 1 dual-output coil. Meaning one coil mounts directly over one of the dual spark plugs for 1 high-voltage output. A second high-voltage output is supplied directly from the same coil (using a plug cable) to one of the dual spark plugs on a corresponding (paired) cylinder on the opposite cylinder bank. Each coil fires 2 spark plugs simultaneously on each of the cylinder banks (one cylinder on compression stroke and one cylinder on exhaust stroke). EXAMPLE: When the #1 cylinder is on compression stroke and ready for spark, the #1 coil will fire one of the dual spark plugs on the #1 cylinder Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Ignition Coil > Page 3625 (directly below the coil). The other dual spark plug on the #1 cylinder will be fired by the #6 coil. At the same time, the #1 coil will fire a "wasted spark" to one of the dual spark plugs at the #6 cylinder as coil #6 also fires a "wasted spark" to one of the dual spark plugs at the #6 cylinder. The firing order is paired at cylinders 1/6, 2/3, 4/7, 5/8. Basic cylinder firing order is 1-8-3-6-5-7-2. Battery voltage is supplied to all of the ignition coils positive terminals from the ASD relay. If the PCM does not see a signal from the crankshaft and camshaft sensors (indicating the ignition key is ON but the engine is not running), it will shut down the ASD circuit. Base ignition timing is not adjustable on the 5.7L V-8 engine. By controlling the coil ground circuits, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The PCM adjusts ignition timing based on inputs it receives from: - The engine coolant temperature sensor - The crankshaft position sensor (engine speed) - The camshaft position sensor (crankshaft position) - The manifold absolute pressure (MAP) sensor - The throttle position sensor - Transmission gear selection Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Ignition Coil > Page 3626 Ignition Coil: Description and Operation Ignition Coil Capacitor One coil capacitor is used. It is located in the right-rear section of the engine compartment. The coil capacitor(s) help dampen the amount of conducted electrical noise to the camshaft position sensor, crankshaft position sensor, and throttle position sensor. This noise is generated on the 12V supply wire to the ignition coils and fuel injectors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Ignition Coil: Service and Repair Ignition Coil REMOVAL Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. An individual ignition coil (1) is used at each cylinder. The coil mounts to the top of the valve cover with 2 bolts (2). The bottom of the coil is equipped with a rubber boot to seal the spark plug to the coil. Inside each rubber boot is a spring. The spring is used for a mechanical contact between the coil and the top of the spark plug. 1. Depending on which coil is being removed, the throttle body air intake tube or intake box may need to be removed to gain access to coil. 2. Unlock electrical connector by moving slide lock first (1). Press on release lock (3) while pulling electrical connector from coil. 3. Disconnect secondary high-voltage cable (2) from coil with a twisting action. 4. Clean area at base of coil with compressed air before removal. 5. Remove two mounting bolts (6) (note that mounting bolts are retained to coil). 6. Carefully pull up coil from cylinder head opening with a slight twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 3629 7. Remove coil from vehicle. 8. Before installing spark plug cables to either the spark plugs or coils, or before installing a coil to a spark plug, apply dielectric grease to inside of boots. INSTALLATION 1. Using compressed air, blow out any dirt or contaminants from around top of spark plug. 2. Before installing spark plug cables to either the spark plugs or coils, or before installing a coil to a spark plug, apply dielectric grease to inside of boots. 3. Position ignition coil into cylinder head opening and push onto spark plug. Twist coil into position. 4. Install 2 coil mounting bolts. Refer to torque specifications. 5. Connect electrical connector to coil by snapping into position. 6. Install cable to coil. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. Refer to Spark Plug Cable Removal for a graphic. 7. If necessary, install throttle body air tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 3630 Ignition Coil: Service and Repair Ignition Coil Capacitor REMOVAL The coil capacitor is located in the right-rear section of the engine compartment. It is attached with a mounting stud and nut. 1. Disconnect electrical connector (5) at capacitor. 2. Remove mounting nut and remove ground strap. 3. Remove capacitor. INSTALLATION 1. Position capacitor to mounting stud. 2. Position ground strap to mounting stud. 3. Tighten nut to 7 N.m (60 in.lbs.) torque. 4. Connect electrical connector to coil capacitor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 5.7L V-8 engine is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches the coils secondary output terminal directly to a spark plug using a rubber boot seal. Each coil is also equipped with a second output terminal. This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank. A separate primary electrical connector is used for each coil. Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The 5.7L engine will not use a conventional distributor. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Dual-Secondary Output, Ignition Coils - 2 knock Sensors - 8 Secondary Ignition Cables - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3637 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3638 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3639 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3640 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 5.7L V-8 engine is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches the coils secondary output terminal directly to a spark plug using a rubber boot seal. Each coil is also equipped with a second output terminal. This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank. A separate primary electrical connector is used for each coil. Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug/coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The 5.7L engine will not use a conventional distributor. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Dual-Secondary Output, Ignition Coils - 2 knock Sensors - 8 Secondary Ignition Cables - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3649 Sensor-Camshaft Position (Gas) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3650 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain/case cover on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel (2) is located at the front of the camshaft. As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3651 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) (2) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right/front side of the timing chain cover or. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3652 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to Torque Specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3657 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3658 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3659 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3660 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3661 CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt (3) and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3666 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3670 Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3671 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3672 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3673 Knock Sensor: Service and Repair REMOVAL Two sensors are used. Each sensor (1) is bolted into the outside of cylinder block below the exhaust manifold. 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor into cylinder block. NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt. Refer to torque specification. 4. Install electrical connector to sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 3678 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... .................................................... 0.045 in (1.14 mm) Torque Spark Plug Torque ............................................................................................................................... .................................... 13 +/- 2 ft.lbs. (18 +/- 3 Nm) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3679 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3680 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3681 Spark Plug: Testing and Inspection The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3682 Spark Plug: Service and Repair REMOVAL Eight of the 16 spark plugs are located under an ignition coil; the other 8 are not. If spark plug being removed is under coil, coil must be removed to gain access to spark plug. Refer to Ignition Coil Removal/Installation and observe all CAUTIONS and WARNINGS. Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil (if coil removal is necessary), spray compressed air around coil base at cylinder head cover. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 5. Inspect spark plug condition. INSTALLATION 1. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into cylinder head by hand to avoid cross threading aluminum threads. To aid in installation, attach a piece of rubber hose, or an old spark plug boot to spark plug. 3. The 5.7L V-8 is equipped with torque critical design spark plugs. Do not exceed 15 ft.lbs. torque. Tighten spark plugs. Refer to torque specifications. 4. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 5. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. 6. Install ignition coil(s) to necessary spark plugs. 7. Install spark plug cables to remaining spark plugs. Remember to apply dielectric grease to inside of boots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 3689 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 3690 Overdrive Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 3691 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3695 Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3696 Pressure Regulating Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3697 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3698 Pressure Regulating Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3699 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3703 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3704 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3705 Solenoid-Brake Transmission Shift Interlock Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3709 Shift Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3710 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3711 Shift Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3712 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams Torque Converter Clutch Solenoid: Diagrams Solenoid-Locker-Front (5.7L Off Road) Solenoid-Locker-Rear (Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations Starter Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3724 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3725 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3726 Transfer Case Actuator: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The tow/haul indicator consists of the text "TOW/HAUL", which appears in the lower portion of the odometer/trip odometer indicator Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "TOW/ HAUL" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The tow/haul indicator is serviced as a unit with the VFD in the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the Off position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tow/haul indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the Off position of the tow/haul switch has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The transmission over-temperature indicator consists of a stencil-like cutout of the text "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED. For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation Four Wheel Drive Indicator Lamp: Description and Operation A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The service 4WD indicator consists of the text "SERV 4WD", which appears in the lower portion of the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "SERV 4WD" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the VFD in the instrument cluster. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TCCM over the Programmable Communications Interface (PCI) data bus. The service 4WD indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the service 4WD indicator for the following reasons: - Service 4WD Lamp-On Message - Each time the cluster receives a service 4WD lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-off message from the TCCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for five seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 3750 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 3751 In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 3752 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3780 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3785 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3786 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3787 Control Module: Diagrams Module-Final Drive Control (Off Road) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3788 Module-Transfer Case Control C1 (Electronic 4x4) Module-Transfer Case Control C2 (Electric 4x4) Module-Transfer Case Control C3 (Electric 4x4) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3789 Control Module: Description and Operation The Transfer Case Control Module (TCCM) (2) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel (1). The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3790 - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for atleast 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3791 - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 ± seconds 100 msec. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel, (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds ± 50 msec . and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3792 following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3798 Sensor-Line Pressure (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3799 Fluid Pressure Sensor/Switch: Description and Operation SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3800 Fluid Pressure Sensor/Switch: Service and Repair SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3804 Switch-Tow/Haul Overdrive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3805 Overdrive Switch: Description and Operation SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3806 Overdrive Switch: Service and Repair SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3807 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3814 Transmission Speed Sensor: Diagrams Sensor-Input Speed (RFE) Sensor-Output Speed (RFE) Sensor-Output Speed (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed Transmission Speed Sensor: Description and Operation Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: . Torque converter clutch slippage . Torque converter element speed ratio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed > Page 3817 Transmission Speed Sensor: Description and Operation Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed Transmission Speed Sensor: Service and Repair Sensor-Input Speed Sensor-Input Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed > Page 3820 Transmission Speed Sensor: Service and Repair Sensor-Output Speed Sensor-Output Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Sensor-Transmission Range (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 3824 Transmission Temperature Sensor/Switch: Description and Operation SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations > Page 3829 Switch-Axle Lock (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 3834 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 3835 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 3836 Switch-Transfer Case Selector (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Four Wheel Drive Selector Switch: Description and Operation NV243 SWITCH-SELECTOR DESCRIPTION The selector switch assembly (1) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: ^ the 2WD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 3839 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 3840 Four Wheel Drive Selector Switch: Description and Operation NV244 GenII SWITCH-TRANSFER CASE SELECTOR DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: ^ the AWD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Gear Sensor/Switch: Locations Left Transmission (RFE) Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 3844 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 3845 Gear Sensor/Switch: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Sensor-Transfer Case Position (MTC Except Power Wagon) Sensor-Transfer Case Position (MTC Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 Gear Sensor/Switch: Description and Operation NV243 Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 3848 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 3849 Gear Sensor/Switch: Description and Operation NV244 GenII Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 3850 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 Gear Sensor/Switch: Service and Repair NV243 ASSEMBLY-SHIFT MOTOR/MODE SENSOR REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 > Page 3853 Gear Sensor/Switch: Service and Repair NV244 GenII REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3862 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3863 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0340/P0344 Set NUMBER: 18-015-09 GROUP: Vehicle Performance DATE: May 9, 2009 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: MIL Illumination Due To Diagnostic Trouble Code P0340 Or P0344 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2002-2003 DN Durango 2002 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (DR) Ram Truck 2004 (AN) Dakota 2005-2006 (ND) Dakota 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2006 (PT) Chrysler PT Cruiser 2005 - 2006 (TJ) Wrangler 2005 - 2006 (TJ) Wrangler (International) NOTE: This bulletin applies to: ^ DR vehicles equipped with a 3.7L/4.7L/5.7L engine (sales code EKG, EVA, EVD, EZA or EZB) ^ 2002 LH vehicles equipped with a 2.7L or 3.5L engine (sales code EER, EES, EGG, EGG, EGK or EGJ) ^ 2003 and 2004 LH vehicles equipped with a 2.7L engine (sales code EER) ^ LX/LE vehicles equipped with a 2.7L/3.5L or 5.7L engine (sales code EER, EGG or EZB) ^ JR vehicles equipped with a 2.7L engine (sales code EER or EER) ^ TJ vehicles equipped with a 4.0L engine (sales code ERH) ^ AN vehicles equipped with a 3.7L or 4.7L engine (sales code EGK or EVA) ^ ND vehicles equipped with a 3.7L or 4.7L engine (sales code EGK, EVA or EVC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3868 ^ PT vehicles equipped with a 2.4L engine (sales code EDZ) ^ DN vehicles equipped with a 4.7L engine (sales code EVA) SYMPTOM/CONDITION: The software contains the following improvements for all customers: ^ A MIL illumination for P0340 - Camshaft Position Sensor Circuit - Bank 1 Sensor 1 ^ A MIL illumination for P0344 - Camshaft Position Sensor Intermittent - Bank 1 Sensor 1 DIAGNOSIS: Using a Scan Tool (DRBIII(R) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TECHCONNECT, Refer To 8 Electrical/Electronic Control Modules/Powertrain Control Module - Standard Procedure PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach it near the VECI label. REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3869 NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3870 NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE FOR EXPORT VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2006 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. 3. Log into DealerCONNECT. Proceed to: Service / Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3871 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3876 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3877 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3878 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3879 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle Technical Service Bulletin # 18-013-05A Date: 050419 Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle NUMBER: 18-013-05 REV. A GROUP: Vehicle Performance DATE: April 19, 2005 THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-013-05, DATED March 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 2004 MODEL YEAR VEHICLES. SUBJECT: Flash: Idle Fluctuation/Diagnostic Trouble Codes OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004** - 2005 (HB) Durango **2004** - 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before Feb. 21, 2005 (MDH 0221XX). SYMPTOM/CONDITION: The vehicle operator may experience rough idle or idle fluctuation or a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following Diagnostic Trouble Codes (DTC's): ^ DTC P0171 - Fuel System Lean - Bank 1 ^ DTC P0174 - Fuel System Lean - Bank 2 NOTE: If DTC's P0171 or P0174 are present, check the long term fuel adaptives. If they are over 33%, further hardware diagnostics are required. If they are under 33% follow the Repair Procedure. DIAGNOSIS: Using a Scan Tool (DRBIII(R) or StarSCAN) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: There are three separate Repair Procedures. One for DR vehicles and two for HB vehicles. NOTE:There are two methods to download flash files to StarSCAN. The first (preferred) method is to download the flash files to the StarSCAN from the internet. The second method is to download the flash files from the StarSCAN Software Update CD. PARTS REQUIRED: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3884 SPECIAL TOOLS/EQUIPMENT REQUIRED: VEHICLES UPDATED USING StarSCAN POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Vehicles Using DRBIII(R) NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3885 a. "DRBIII(R) Standalone" b. "1998 - 20045 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 11. If the vehicle is a 2003 or later AN or 2002 or later DN or DR model, proceed to Step # 12. If not proceed Step # 15. 12. Using the DRBIII(R), determine the pinion factor stored in the Controller Anti-lock Brakes (CAB) and record it on the work order for later reference. 13. Turn the ignition switch to the "Off" position. 14. Disconnect the CAB module electrical connectors. Proceed to Step # 15. 15. Connect the DRBIII(R) to the vehicle. 16. Turn the ignition to the "Run" position (engine not running). 17. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 18. 18. If the vehicle is a 2003 and later AN or 2002 or later DN or DR model, proceed to Step # 19. If not proceed to Step # 23. 19. Turn the ignition to the "Off" position. 20. Connect the CAB electrical connectors. 21. Turn the ignition switch to the "Run" position (engine not running). 22. Using the DRBIII(R), check the pinion factor in the CAB to be sure that it was not erased during the flash process. If the pinion factor is not present or is not correct, enter the correct pinion factor. Proceed to Step # 23. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules. (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" Screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3886 NOTE: The following step is required by law. 23. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Using the Internet to Retrieve the Flash File NOTE: The latest released version of the StarSCAN software must be installed on the StarSCAN tool before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed. NOTE: The StarSCAN diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership's network. For instruction on setting up your StarSCAN for the dealer's network; refer to the StarSCAN Quick Start Networking Guide available on the website under the "download center". NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (optional). 3. Retrieve the old PCM part number. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options". d. Select "ECU Flash" e. Record the "Part Number", displayed on the "Flash PCM" screen, for later reference. 4. If the StarSCAN is connected to the dealer's network drop and the vehicle, proceed to Step # 5. If the StarSCAN is not connected to the dealer's network drop and the vehicle, proceed to Step # 9 5. select "Browse for new file". 6. Select the appropriate calibration. 7. Select "Download to Scantool". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3887 8. Select "Close" after the download is complete. Proceed to Step # 10. 9. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the "Home" screen: a. Select "Flash Download". b. Select "Enter information manually". Press the "Next" button and follow the on screen instructions. c. Select the appropriate calibration. d. Select "Download to Scantool". e. Select "Close" after the download is complete. 10. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 11. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 12. Download the file from StarSCAN to the vehicle. Using StarSCAN at the "Home" screen: a. Select "ECU View" b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select "More Options" d. Select "ECU Flash" e. Highlight the appropriate PCM "Calibration" from the list. f. Select "Update Controller" g. When update is completed, select "OK" 13. Verify that the PCM part number has updated. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options". d. Select "ECU Flash" e. Verify that the "Part Number", displayed on the "Flash PCM" screen, has changed to the updated part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules. (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" Screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law. 14. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Using Software Update CD to Retrieve the Flash NOTE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to website under the "Latest News" link. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3888 For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old PCM part number. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 2). 3. Insert the StarSCAN Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN Software Update CD will start automatically. a. Select "Controller Flash". b. Follow the on screen instructions. 4. At the "Select the type of information you wish to enter." screen: a. If the old "Part Number" was recorded in Step # 1, proceed to Step # 5. b. If the old "Part Number" is not known, proceed to Step # 6. 5. Select "Enter part number". a. Follow the on screen instructions. Enter the "Part Number" (use capital letters) recorded in Step # 1 when prompted to do so. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. b. Proceed to Step # 7. 6. Select "Enter YME Information". a. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3889 b. Proceed to Step # 7. 7. Using the mouse highlight the appropriate '~Calibration" a. Select "Save to USB" b. Follow the on screen instructions. Select "Next" # after each step. Select "Finish" after completing the last step. 8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig. 3). 9. Open the hood, install a battery charger and verify the battery state is above 12.5 volts. 10. Connect the StarSCAN to the vehicle. 11. Power ON the StarSCAN. 12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the "Home" screen: a. Select "Flash Download" b. Select "Use USB device" c. Follow the on screen instructions. Select "Next" # after each step. Select "Finish" after completing the last step. d. At the "Flash File List" screen, highlight the appropriate PCM "Calibration" e. Select "Download to Scantool" f. When the download is complete, select "Close" 13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select "More Options" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3890 d. Select "ECU Flash" e. Highlight the appropriate PCM "Calibration" from the list. f. Select "Update Controller" g. When update is completed, select "OK" 14. Verify that the PCM part number has updated. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options". d. Select "ECU Flash" e. Verify that the "Part Number", displayed on the "Flash PCM" screen, has changed to the updated part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules. (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" Screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ETC Lamp ON/DTC's P2110/P2118 NUMBER: 14-003-10 GROUP: Fuel DATE: February 16, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 14-002-05, DATED MARCH 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarSCAN(R) or StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: ETC Light Illuminated And/Or Inactive Throttle Body In Cold Ambient Temperatures OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software and replacing the throttle body on DR models only if Service Bulletin 14-002-05 has not been performed. MODELS: 2003 - 2005 (DR) Ram Truck 2004-2005 (HB) Durango NOTE: This Bulletin Applies To Vehicles Equipped With 5.7L Engines (Sales Code EZA). SYMPTOM/CONDITION: Customers may experience any of the following Electronic Throttle Control (ETC) system symptoms at startup in extreme cold ambient temperatures (Below 0°F (minus 18°C)): ^ Partial Return From Cold Start Fast Idle ^ No RPM Increase When Accelerator Pedal Is Moved ^ ETC Light Illuminated and Diagnostic Trouble Code P2110 - Throttle Actuator Control System Forced Limited RPM set ^ ETC Light Illuminated and Diagnostic Trouble Code 2118 - Throttle Actuator Control Motor Current Range/Performance set This condition has been corrected by updating the PCM software to aggressively shake the throttle blade at start-up to break any ice that may be present. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3896 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is this a DR vehicle? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 3 2. Has Service Bulletin 14-005-05 been performed on this vehicle? a. Yes >> proceed to Step # 3 b. No >> Using the procedures outlined on DealerCONNECT/TechCONNECT, remove the throttle body and install the appropriate throttle body listed in the Parts Required section and proceed to Step # 3 NOTE: The HB body PCM may not support abort recovery. If this update is interrupted or aborted for any reason, the PCM may be unable to display a flash part number requiring the PCM to be replaced. NOTE: If this flash process on DR bodies is interrupted/aborted, the flash should be restarted. 3. Reprogram the PCM with the latest software. a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 14-003-10 > Feb > 10 > Engine Controls - ETC Lamp ON/DTC's P2110/P2118 > Page 3897 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0340/P0344 Set NUMBER: 18-015-09 GROUP: Vehicle Performance DATE: May 9, 2009 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: MIL Illumination Due To Diagnostic Trouble Code P0340 Or P0344 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2002-2003 DN Durango 2002 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (DR) Ram Truck 2004 (AN) Dakota 2005-2006 (ND) Dakota 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2006 (PT) Chrysler PT Cruiser 2005 - 2006 (TJ) Wrangler 2005 - 2006 (TJ) Wrangler (International) NOTE: This bulletin applies to: ^ DR vehicles equipped with a 3.7L/4.7L/5.7L engine (sales code EKG, EVA, EVD, EZA or EZB) ^ 2002 LH vehicles equipped with a 2.7L or 3.5L engine (sales code EER, EES, EGG, EGG, EGK or EGJ) ^ 2003 and 2004 LH vehicles equipped with a 2.7L engine (sales code EER) ^ LX/LE vehicles equipped with a 2.7L/3.5L or 5.7L engine (sales code EER, EGG or EZB) ^ JR vehicles equipped with a 2.7L engine (sales code EER or EER) ^ TJ vehicles equipped with a 4.0L engine (sales code ERH) ^ AN vehicles equipped with a 3.7L or 4.7L engine (sales code EGK or EVA) ^ ND vehicles equipped with a 3.7L or 4.7L engine (sales code EGK, EVA or EVC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3902 ^ PT vehicles equipped with a 2.4L engine (sales code EDZ) ^ DN vehicles equipped with a 4.7L engine (sales code EVA) SYMPTOM/CONDITION: The software contains the following improvements for all customers: ^ A MIL illumination for P0340 - Camshaft Position Sensor Circuit - Bank 1 Sensor 1 ^ A MIL illumination for P0344 - Camshaft Position Sensor Intermittent - Bank 1 Sensor 1 DIAGNOSIS: Using a Scan Tool (DRBIII(R) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TECHCONNECT, Refer To 8 Electrical/Electronic Control Modules/Powertrain Control Module - Standard Procedure PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach it near the VECI label. REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3903 NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3904 NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE FOR EXPORT VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2006 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. 3. Log into DealerCONNECT. Proceed to: Service / Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. TIME ALLOWANCE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3905 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3910 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3911 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3912 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3913 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3914 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3915 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3916 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3917 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3918 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3919 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3924 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3925 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3926 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3927 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3928 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3929 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3930 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3931 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3932 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3933 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3935 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3936 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3937 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3938 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3939 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3940 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3941 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3942 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0430/P0420 Set NUMBER: 18-028-05 REV. A GROUP: Vehicle Performance DATE: July 20, 2005 THIS BULLETIN REVISES SERVICE BULLETIN 18-028-05, DATED JUNE 14, 2005 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISIONS ADDS A NEW PART NUMBER FOR AN OXYGEN SENSOR OMITTED FROM THE ORIGINAL BULLETIN. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2005. SUBJECT: Flash: Diagnostic Trouble Code P0430, P0420 - Catalyst Efficiency OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) and replacing the downstream oxygen sensor. MODELS: 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before June 1, 2005 (MDH 0601XX). SYMPTOM/CONDITION: Customers may experience a MIL light with Diagnostic Trouble Code (DTC) - P0430 or P0420 Catalyst Efficiency. DIAGNOSIS: If the DTC is present, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRE NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Using the procedure outlined on TeChCONNECT, remove the down stream oxygen sensor and install the appropriate part number listed above. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3947 REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DealerCONNECT: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part #" on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part #" recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TeChCONNECT and follow the instructions on TeChCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TeChCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 15. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3948 Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). REPAIR PROCEDURE FOR EXPORT VEHICLES USING DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "ECM part #" on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3949 3. Log into DealerCONNECT. Proceed to: Service/Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. 6. Download the new calibration to the PC. 7. Using the "DRBIII - WINFLASH II" application on the PC, download the flash calibration file to the DRBIII(R) from the PC. 8. Disconnect the DRBIII(R) from the PC and NULL modem cable. 9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition switch to the "Run" position (engine not running). 12. Reprogram the ECM by downloading the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. 15. Update the Sentry Key Immobilizer Module (SKIM) or Sentry Key Remote Entry Module (SKREEM), Secret Key data as necessary. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-05A > Jul > 05 > Engine Controls - MIL ON/DTC's P0430/P0420 Set > Page 3950 16. Type the necessary information on the "Authorized Software Update" label, p/n 04275086AB and attach near the VECI label(Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle Technical Service Bulletin # 18-013-05A Date: 050419 Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle NUMBER: 18-013-05 REV. A GROUP: Vehicle Performance DATE: April 19, 2005 THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-013-05, DATED March 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 2004 MODEL YEAR VEHICLES. SUBJECT: Flash: Idle Fluctuation/Diagnostic Trouble Codes OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004** - 2005 (HB) Durango **2004** - 2005 (DR/DH) Ram Truck NOTE: This Bulletin Applies To Vehicle Equipped With 5.7L engines (Sales Code EZA) built on or before Feb. 21, 2005 (MDH 0221XX). SYMPTOM/CONDITION: The vehicle operator may experience rough idle or idle fluctuation or a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following Diagnostic Trouble Codes (DTC's): ^ DTC P0171 - Fuel System Lean - Bank 1 ^ DTC P0174 - Fuel System Lean - Bank 2 NOTE: If DTC's P0171 or P0174 are present, check the long term fuel adaptives. If they are over 33%, further hardware diagnostics are required. If they are under 33% follow the Repair Procedure. DIAGNOSIS: Using a Scan Tool (DRBIII(R) or StarSCAN) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: There are three separate Repair Procedures. One for DR vehicles and two for HB vehicles. NOTE:There are two methods to download flash files to StarSCAN. The first (preferred) method is to download the flash files to the StarSCAN from the internet. The second method is to download the flash files from the StarSCAN Software Update CD. PARTS REQUIRED: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3955 SPECIAL TOOLS/EQUIPMENT REQUIRED: VEHICLES UPDATED USING StarSCAN POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Vehicles Using DRBIII(R) NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3956 a. "DRBIII(R) Standalone" b. "1998 - 20045 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 11. If the vehicle is a 2003 or later AN or 2002 or later DN or DR model, proceed to Step # 12. If not proceed Step # 15. 12. Using the DRBIII(R), determine the pinion factor stored in the Controller Anti-lock Brakes (CAB) and record it on the work order for later reference. 13. Turn the ignition switch to the "Off" position. 14. Disconnect the CAB module electrical connectors. Proceed to Step # 15. 15. Connect the DRBIII(R) to the vehicle. 16. Turn the ignition to the "Run" position (engine not running). 17. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 18. 18. If the vehicle is a 2003 and later AN or 2002 or later DN or DR model, proceed to Step # 19. If not proceed to Step # 23. 19. Turn the ignition to the "Off" position. 20. Connect the CAB electrical connectors. 21. Turn the ignition switch to the "Run" position (engine not running). 22. Using the DRBIII(R), check the pinion factor in the CAB to be sure that it was not erased during the flash process. If the pinion factor is not present or is not correct, enter the correct pinion factor. Proceed to Step # 23. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules. (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" Screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3957 NOTE: The following step is required by law. 23. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Using the Internet to Retrieve the Flash File NOTE: The latest released version of the StarSCAN software must be installed on the StarSCAN tool before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed. NOTE: The StarSCAN diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership's network. For instruction on setting up your StarSCAN for the dealer's network; refer to the StarSCAN Quick Start Networking Guide available on the website under the "download center". NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (optional). 3. Retrieve the old PCM part number. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options". d. Select "ECU Flash" e. Record the "Part Number", displayed on the "Flash PCM" screen, for later reference. 4. If the StarSCAN is connected to the dealer's network drop and the vehicle, proceed to Step # 5. If the StarSCAN is not connected to the dealer's network drop and the vehicle, proceed to Step # 9 5. select "Browse for new file". 6. Select the appropriate calibration. 7. Select "Download to Scantool". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3958 8. Select "Close" after the download is complete. Proceed to Step # 10. 9. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the "Home" screen: a. Select "Flash Download". b. Select "Enter information manually". Press the "Next" button and follow the on screen instructions. c. Select the appropriate calibration. d. Select "Download to Scantool". e. Select "Close" after the download is complete. 10. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 11. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 12. Download the file from StarSCAN to the vehicle. Using StarSCAN at the "Home" screen: a. Select "ECU View" b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select "More Options" d. Select "ECU Flash" e. Highlight the appropriate PCM "Calibration" from the list. f. Select "Update Controller" g. When update is completed, select "OK" 13. Verify that the PCM part number has updated. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options". d. Select "ECU Flash" e. Verify that the "Part Number", displayed on the "Flash PCM" screen, has changed to the updated part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules. (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" Screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law. 14. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Using Software Update CD to Retrieve the Flash NOTE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to website under the "Latest News" link. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3959 For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old PCM part number. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 2). 3. Insert the StarSCAN Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN Software Update CD will start automatically. a. Select "Controller Flash". b. Follow the on screen instructions. 4. At the "Select the type of information you wish to enter." screen: a. If the old "Part Number" was recorded in Step # 1, proceed to Step # 5. b. If the old "Part Number" is not known, proceed to Step # 6. 5. Select "Enter part number". a. Follow the on screen instructions. Enter the "Part Number" (use capital letters) recorded in Step # 1 when prompted to do so. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. b. Proceed to Step # 7. 6. Select "Enter YME Information". a. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3960 b. Proceed to Step # 7. 7. Using the mouse highlight the appropriate '~Calibration" a. Select "Save to USB" b. Follow the on screen instructions. Select "Next" # after each step. Select "Finish" after completing the last step. 8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig. 3). 9. Open the hood, install a battery charger and verify the battery state is above 12.5 volts. 10. Connect the StarSCAN to the vehicle. 11. Power ON the StarSCAN. 12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the "Home" screen: a. Select "Flash Download" b. Select "Use USB device" c. Follow the on screen instructions. Select "Next" # after each step. Select "Finish" after completing the last step. d. At the "Flash File List" screen, highlight the appropriate PCM "Calibration" e. Select "Download to Scantool" f. When the download is complete, select "Close" 13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select "More Options" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-013-05A > Apr > 05 > Engine Controls - MIL ON/DTC's P0171/P0174/Rough Idle > Page 3961 d. Select "ECU Flash" e. Highlight the appropriate PCM "Calibration" from the list. f. Select "Update Controller" g. When update is completed, select "OK" 14. Verify that the PCM part number has updated. Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options". d. Select "ECU Flash" e. Verify that the "Part Number", displayed on the "Flash PCM" screen, has changed to the updated part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules. (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" Screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3967 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3968 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3969 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3970 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3971 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3972 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3973 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3974 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3975 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 3976 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3981 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3982 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3983 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3984 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3985 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3986 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3987 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3988 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3989 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3990 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3991 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3992 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3993 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3994 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3995 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3996 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3997 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3998 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3999 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4006 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4007 Overdrive Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4008 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4012 Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4013 Pressure Regulating Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4014 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4015 Pressure Regulating Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4016 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4020 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4021 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4022 Solenoid-Brake Transmission Shift Interlock Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4026 Shift Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4027 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4028 Shift Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4029 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams Torque Converter Clutch Solenoid: Diagrams Solenoid-Locker-Front (5.7L Off Road) Solenoid-Locker-Rear (Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations Starter Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4041 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4042 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4043 Transfer Case Actuator: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4049 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4050 Overdrive Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4051 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4055 Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4056 Pressure Regulating Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4057 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4058 Pressure Regulating Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4059 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4063 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4064 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4065 Solenoid-Brake Transmission Shift Interlock Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4069 Shift Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4070 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4071 Shift Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4072 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams Torque Converter Clutch Solenoid: Diagrams Solenoid-Locker-Front (5.7L Off Road) Solenoid-Locker-Rear (Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Page 4079 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Page 4080 In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Page 4081 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4087 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4092 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4093 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4094 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4095 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4096 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4097 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4098 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications SERVICE FILL Model 48RE ................................................................................................................ ............................................................................... 3.8Liters (4.0 Qt) Model 45RFE/545RFE 4X2 ................................................................................................................. .......................................................................................... 5.2Liters (11.0 Pt) 4X4 .............................. .............................................................................................................................................................. ............... 6.2Liters (13.0 Pt) OVERHAUL * Model 48RE .................................................................................................................. ............................................................................ 14-16L (29-33 Pt) Model 45RFE/545RFE ........................................................................................................................ ..................................................... 14-16L (29-33 Pt) *Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4101 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type .............................................................................................................. Mopar ATF+4 Automatic Transmission Fluid Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4102 Fluid - A/T: Testing and Inspection FLUID DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. FLUID CONTAMINATION Transmission fluid contamination is generally a result of: ^ adding incorrect fluid ^ failure to clean dipstick and fill tube when checking level ^ engine coolant entering the fluid . internal failure that generates debris ^ overheat that generates sludge (fluid breakdown) ^ failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4105 10. Check transmission for leaks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4106 Fluid - A/T: Service and Repair Fluid and Filter Service FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICATION & MAINTENANCE. REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4107 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: Customer Interest A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 4116 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 4117 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 4118 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 4123 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: All Technical Service Bulletins A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 4129 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 4130 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 4131 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 4136 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 4137 Fluid Filter - A/T: Service and Repair FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICATION & MAINTENANCE. REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair Fluid Line/Hose: Service and Repair TRANSMISSION STANDARD PROCEDURE TRANSMISSION COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove dust cap by pulling it straight back off of quick connect fitting. 2. Place disconnect tool Special Tool 8875A onto transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove. CONNECT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4141 1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting. 2. Push in on transmission cooler line until a "click" is heard or felt. 3. Slide dust cap down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step 2. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Bolt, oil pan .......................................................................................................................................... ............................................ 11.8 Nm (105 inch lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4148 Sensor-Line Pressure (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4149 Fluid Pressure Sensor/Switch: Description and Operation SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4150 Fluid Pressure Sensor/Switch: Service and Repair SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The tow/haul indicator consists of the text "TOW/HAUL", which appears in the lower portion of the odometer/trip odometer indicator Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "TOW/ HAUL" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The tow/haul indicator is serviced as a unit with the VFD in the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the Off position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tow/haul indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the Off position of the tow/haul switch has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The transmission over-temperature indicator consists of a stencil-like cutout of the text "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED. For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4168 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4169 Overdrive Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4170 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The tow/haul indicator consists of the text "TOW/HAUL", which appears in the lower portion of the odometer/trip odometer indicator Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "TOW/ HAUL" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The tow/haul indicator is serviced as a unit with the VFD in the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the Off position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tow/haul indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the Off position of the tow/haul switch has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 4177 Switch-Tow/Haul Overdrive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 4178 Overdrive Switch: Description and Operation SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 4179 Overdrive Switch: Service and Repair SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 4180 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4184 Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4185 Pressure Regulating Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4186 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4187 Pressure Regulating Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4188 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4193 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4194 In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4195 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 4223 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Seal-Adapter Housing Seals and Gaskets: Service and Repair Seal-Adapter Housing SEAL-ADAPTER HOUSING REMOVAL 1. Remove the transfer case from the transmission. 2. Using a screw mounted on a slide hammer, remove the adapter housing seal. INSTALLATION 1. Clean the adapter seal bore in the adapter housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the adapter housing using Seal Installer C-3860-A (1). A properly installed seal is flush to the face of the seal bore. 3. Install the transfer case onto the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Seal-Adapter Housing > Page 4228 Seals and Gaskets: Service and Repair Seal-Oil Pump Front SEAL-OIL PUMP FRONT REMOVAL 1. Remove transmission from the vehicle. 2. Remove the torque converter from the transmission. 3. Using a screw mounted in a slide hammer, remove the oil pump front seal. INSTALLATION 1. Clean seal bore of the oil pump of any residue or particles from the original seal. 2. Install new oil seal in the oil pump housing using Seal Installer C-3860-A (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4233 Sensor-Line Pressure (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4234 Fluid Pressure Sensor/Switch: Description and Operation SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4235 Fluid Pressure Sensor/Switch: Service and Repair SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4239 Switch-Tow/Haul Overdrive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4240 Overdrive Switch: Description and Operation SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4241 Overdrive Switch: Service and Repair SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4242 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4249 Transmission Speed Sensor: Diagrams Sensor-Input Speed (RFE) Sensor-Output Speed (RFE) Sensor-Output Speed (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed Transmission Speed Sensor: Description and Operation Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: . Torque converter clutch slippage . Torque converter element speed ratio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed > Page 4252 Transmission Speed Sensor: Description and Operation Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed Transmission Speed Sensor: Service and Repair Sensor-Input Speed Sensor-Input Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed > Page 4255 Transmission Speed Sensor: Service and Repair Sensor-Output Speed Sensor-Output Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Sensor-Transmission Range (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 4259 Transmission Temperature Sensor/Switch: Description and Operation SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4264 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4265 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4266 Solenoid-Brake Transmission Shift Interlock Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4270 Shift Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4271 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4272 Shift Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4273 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection Shift Cable: Testing and Inspection CABLE-GEARSHIFT DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 4278 Shift Cable: Adjustments ADJUSTMENTS - GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 4279 Shift Cable: Service and Repair REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 4280 10. Remove gearshift cable (2) from vehicle. INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The transmission over-temperature indicator consists of a stencil-like cutout of the text "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED. For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Diagrams Assembly - Transmission Throttle Valve (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair Torque Converter: Service and Repair CONVERTER-TORQUE REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper or crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub O-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 13 mm (1/2 inch) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams Torque Converter Clutch Solenoid: Diagrams Solenoid-Locker-Front (5.7L Off Road) Solenoid-Locker-Rear (Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 4320 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation Transmission Cooler: Description and Operation COOLER-TRANSMISSION OIL DESCRIPTION ALL VEHICLES An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler and OPERATION GAS ENGINES Transmission oil is routed through the cooler where heat is removed from the transmission oil before returning to the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Page 4324 Transmission Cooler: Service and Repair COOLER-TRANSMISSION OIL REMOVAL 5.7L ENGINE 1. Place a drain pan under the oil cooler lines. 2. Disconnect the transmission oil cooler line quick-connect fitting at the cooler outlet using the quick connect release tool 6935. Plug the cooler lines to prevent oil leakage. 3. Unsnap the transmission cooler tubes from the radiator tank clips. 4. Remove the bolt attaching the transmission cooler to the radiator. 5. Remove oil cooler from the vehicle. Take care not to damage the radiator core or transmission cooler tubes. INSTALLATION 1. Position the transmission cooler tubes to the front of the radiator by sliding brackets into slots on radiator inlet tank. 2. Snap the transmission cooler tubes into the clips on the side of the radiator tank. 3. Install the transmission cooler attaching bolt. Tighten the bolt to 16 Nm (140 inch lbs.). 4. Inspect the quick connect fittings for debris and install the quick connect fitting on the cooler tube until an audible "click" is heard. Pull apart the connection to verify proper installation and install the secondary latches. 5. Start the engine and check all fittings for leaks. 6. Check the fluid level in the automatic transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4334 Transmission Speed Sensor: Diagrams Sensor-Input Speed (RFE) Sensor-Output Speed (RFE) Sensor-Output Speed (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed Transmission Speed Sensor: Description and Operation Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: . Torque converter clutch slippage . Torque converter element speed ratio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed > Page 4337 Transmission Speed Sensor: Description and Operation Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed Transmission Speed Sensor: Service and Repair Sensor-Input Speed Sensor-Input Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed > Page 4340 Transmission Speed Sensor: Service and Repair Sensor-Output Speed Sensor-Output Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Sensor-Transmission Range (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 4344 Transmission Temperature Sensor/Switch: Description and Operation SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation Valve Body: Description and Operation BODY-VALVE DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components: ^ Solenoid switch valve ^ Manual valve ^ Low/reverse switch valve ^ 5 Accumulators ^ 7 check balls OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Page 4348 SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and fifth gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically by a cable to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the "roostercomb" of the TRS selector plate (1). LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal Valve Body: Service and Repair Removal BODY-VALVE REMOVAL NOTE: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect wires at the solenoid and pressure switch assembly connector. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan. 6. Remove the primary oil filter (1) from valve body. 7. Remove bolts (1) attaching valve body to transmission case. 8. Lower the valve body and work the electrical connector out of transmission case. 9. Separate the valve body from the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4351 Valve Body: Service and Repair Disassembly BODY-VALVE DISASSEMBLY 1. Remove the bolts (1) holding the solenoid and pressure switch assembly to the valve body. Do not remove the screws on the top of the solenoid and pressure switch assembly. 2. Separate the solenoid and pressure switch assembly from the valve body. 3. Remove the screw holding the detent spring (2) onto the valve body. 4. Remove the detent spring (2) from the valve body. 5. Remove the TRS selector plate (1) from the valve body and the manual valve. 6. Remove the clutch passage seals (3) from the valve body, if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4352 7. Remove the screws holding the accumulator cover onto the valve body. 8. Remove the accumulator springs and pistons (1, 6-9) from the valve body. Note which accumulator piston and spring belong in each location. 9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body. 10. Remove the screws holding the valve body to the valve body transfer plate. 11. Remove the transfer plate from the valve body. Note the location of all check balls. 12. Remove the check balls from the valve body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4353 13. Remove the retainers securing the solenoid switch valve (1), manual valve (2), and the low/reverse switch valve (3) from the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4354 Valve Body: Service and Repair Cleaning CLEANING Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4355 Valve Body: Service and Repair Inspection INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and nines should drop freely into the bores Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4356 Inspect all the fluid seals on the valve body. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4357 Valve Body: Service and Repair Removal BODY-VALVE REMOVAL NOTE: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect wires at the solenoid and pressure switch assembly connector. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan. 6. Remove the primary oil filter (1) from valve body. 7. Remove bolts (1) attaching valve body to transmission case. 8. Lower the valve body and work the electrical connector out of transmission case. 9. Separate the valve body from the transmission. Disassembly BODY-VALVE DISASSEMBLY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4358 1. Remove the bolts (1) holding the solenoid and pressure switch assembly to the valve body. Do not remove the screws on the top of the solenoid and pressure switch assembly. 2. Separate the solenoid and pressure switch assembly from the valve body. 3. Remove the screw holding the detent spring (2) onto the valve body. 4. Remove the detent spring (2) from the valve body. 5. Remove the TRS selector plate (1) from the valve body and the manual valve. 6. Remove the clutch passage seals (3) from the valve body, if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4359 7. Remove the screws holding the accumulator cover onto the valve body. 8. Remove the accumulator springs and pistons (1, 6-9) from the valve body. Note which accumulator piston and spring belong in each location. 9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body. 10. Remove the screws holding the valve body to the valve body transfer plate. 11. Remove the transfer plate from the valve body. Note the location of all check balls. 12. Remove the check balls from the valve body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4360 13. Remove the retainers securing the solenoid switch valve (1), manual valve (2), and the low/reverse switch valve (3) from the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly. Cleaning CLEANING Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Inspection Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4361 INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and nines should drop freely into the bores Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4362 Inspect all the fluid seals on the valve body. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Assembly ASSEMBLY 1. Lubricate valves, springs, and the housing valve bores with clean transmission fluid. 2. Install solenoid switch valve (1), manual valve (2), and the low/reverse switch valve (3) into the valve body. 3. Install the retainers to hold each valve into the valve body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4363 4. Install the valve body check balls into their proper locations. 5. Position the transfer plate onto the valve body. 6. Install the screws to hold the transfer plate to the valve body. Tighten the screws to 5.6 Nm (50 inch lbs.). 7. Install the accumulator pistons (1, 6-9) and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumulator piston (6) has only one spring. 8. Position the accumulator cover onto the valve body. 9. Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 7 Nm (60 inch lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4364 10. Install the TRS selector plate (1) onto the valve body and the manual valve. 11. Position the detent spring (2) onto the valve body. 12. Install the screw to hold the detent spring (2) onto the valve body. Tighten the screw to 4.5 Nm (40 inch lbs.). 13. Install new clutch passage seals (3) onto the valve body, if necessary. 14. Install the solenoid and pressure switch assembly onto the valve body. 15. Install the bolts (1) to hold the solenoid and pressure switch assembly onto the valve body. Tighten the bolts to 5.7 Nm (50 inch lbs.). Tighten the bolts adjacent to the arrows cast into the bottom of the transfer plate first. Installation INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4365 1. Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn. 2. Place TRS selector plate in the PARK position. 3. Place the transmission in the PARK position. 4. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly. 5. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever. 6. Seat valve body in case and install one or two bolts to hold valve body in place. 7. Tighten valve body bolts alternately and evenly to 12 Nm (105 inch lbs.) torque. CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 8. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 9. Place replacement filter (1) in position on valve body and into the oil pump. 10. Install screw to hold filter to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 11. Connect the solenoid and pressure switch assembly connector. 12. Install oil pan. Tighten pan bolts to 12 Nm (105 inch lbs.) torque. 13. Lower vehicle and fill transmission with Mopar(R) ATF +4. 14. Check and adjust gearshift cable, if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair DISC CLUTCH REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool through clutch disc and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. INSTALLATION 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: ^ V6 & V8 Engines - 50 Nm (37 ft. lbs.) ^ V10 & Diesel Engines - 30 Nm (22.5 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 4370 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). 10. Apply light coat of Mopar high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 4371 12. Install release lever and bearing in clutch housing. Verify spring clip (2) that retain lever on pivot ball (4) and release bearing (3) clips (1) on lever (1) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4377 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair LINKAGE REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding the to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 4381 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair LINKAGE REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding the to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 4385 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair LINKAGE REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding the to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 4389 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Clutch Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4393 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4394 Switch-Clutch Interlock (M/T) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4395 Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair BEARING CLUTCH RELEASE REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, lever pivot ball stud (1), and release lever pivot surface with Mopar(R) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install clutch housing, if removed. 6. Install transmission and transfer case. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair Clutch Release Fork: Service and Repair BEARING CLUTCH RELEASE REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, lever pivot ball stud (1), and release lever pivot surface with Mopar(R) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install clutch housing, if removed. 6. Install transmission and transfer case. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair BEARING PILOT REMOVAL 1. Remove transmission assembly from the vehicle. 2. Remove pressure plate (2) and clutch disc. 3. Remove pilot bearing with an internal puller and slide hammer to remove. INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Install new bearing (1) with clutch alignment tool (2) and letter side of the bearing (3) facing the transmission. Bearing should be flush with edge of bearing bore. CAUTION: Do not allow bearing to become cocked and do not recess bearing. 3. Install clutch disc, pressure plate and transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate Bolts - V10 .................................................................................................................. ................................................... 30 Nm (22.5 ft. lbs.) Tighten bolts evenly and a few threads at a time in a diagonal pattern Pressure Plate Bolts-Diesel .. .............................................................................................................................................................. .... 30 Nm (22.5 ft. lbs.) V6 & V8 Engines ............................................................................................ ......................................................................................... 50 Nm (37 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4408 Pressure Plate: Service and Repair DISC CLUTCH REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool through clutch disc and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. INSTALLATION 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: ^ V6 & V8 Engines - 50 Nm (37 ft. lbs.) ^ V10 & Diesel Engines - 30 Nm (22.5 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4409 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). 10. Apply light coat of Mopar high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4410 12. Install release lever and bearing in clutch housing. Verify spring clip (2) that retain lever on pivot ball (4) and release bearing (3) clips (1) on lever (1) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4417 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4422 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations Starter Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair COVER-DIFFERENTIAL REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug. 3. Remove cover bolts. 4. Remove cover and drain lubricant. INSTALLATION 1. Apply a 6.35mm (1/4 inch) bead of Mopar Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover and identification tag. Tighten cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.). 3. Fill differential to specifications. 4. Install fill plug. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations Starter Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Switch, Differential Lock > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Switch, Differential Lock > Component Information > Locations > Page 4438 Switch-Axle Lock (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4443 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4444 Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4445 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front FRONT AXLE C205F .......................................................................................................................... ............................................................................ 56 oz. (1.6 Liters) * 9 1/4 AA .................................. .............................................................................................................................................................. .. 76 oz. (2.2 Liters) * 9 1/4 AA EL ....................................................................................................... ..................................................................................... 76 oz. (2.2 Liters) * *± 1 oz (0.03 L) Rear REAR AXLE 9 1/4 ............................................................................................................................... ........................................................................ 72 oz. (2.1 L)*** (a) 10 1/2 AA .................................... .......................................................................................................................................................... 85 oz. (2.5 Liters) (a) 10 1/2 AA EL ..................................................................................................... ................................................................................... 85 oz. (2.5 Liters) (a) 11 1/2 AA ...................... .............................................................................................................................................................. ........ 122 oz. (3.6 Liters) (a) 248RBI (DANA 60) ................................................................................. ............................................................................................ 46 oz. (2.8 L)**** (a) (a)± 1 oz (0.03 L) *** With Trac-Lok add 4 oz. (118 ml) of Limited Slip Additive. **** Add 5 oz. (147 ml) of Limited Slip Additive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4448 Fluid - Differential: Fluid Type Specifications Front Axle NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. FRONT AXLE C205F .......................................................................................................................... ......................................................... Mopar Gear Lubricant 75W-90 9 1/4 AA ................................... ............................................................................................................................ Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA EL ......................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 NOTE: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Rear Axle NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. REAR AXLE 9 1/4 ............................................................................................................................... ..................................... Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL ....................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 248 RBI .............................................................................. ....................................................................................... Mopar Gear & Axle Lubricant SAE 90 NOTE: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 4449 Fluid - Differential: Service and Repair 1. Raise and support the vehicle. 2. Remove the lubricant fill hole plug from the differential housing cover. 3. Remove the differential housing cover and drain the lubricant from the housing. 4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning. 5. Remove the sealant from the housing and cover surfaces. Use solvent to clean the mating surfaces. Fig. 3 6. Apply a bead of Mopar Silicone Rubber Sealant, or equivalent, to the housing cover (Fig. 6). Install the housing cover within 5 minutes after applying the sealant. 7. Install the cover and any identification tag. Tighten the cover bolts in a crisscross pattern to 41 Nm (30 ft. lbs.) torque. 8. Refill the differential with Mopar Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. Refer to Specifications for the quantity necessary. 9. Install the fill hole plug and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair Differential Output Shaft Bearing: Service and Repair BEARING-AXLE REMOVAL 1. Remove half shaft, axle shaft and seal. 2. Install axle shaft bearing Remover C-4660-A (3) in the bearing (1). Then tighten the nut (2) to spread the remover in the bearing. 3. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut (3) to draw the bearing out. 4. Inspect axle shaft tube bore for roughness and burrs. INSTALLATION 1. Wipe the axle shaft tube bore clean. 2. Install axle shaft bearing with Installer 5063 (1) and Handle C-4171 (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 4454 3. Install a new axle shaft seal with Installer 8694 (1). 4. Lubricate seal lip with gear lubricant. 5. Insert axle shaft through seal, bearing and engage it into side gear splines. Push firmly on the axle shaft to engage the snap-ring. 6. Install axle shaft o-ring. 7. Install skid plate, if necessary. 8. Install half shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F Seals and Gaskets: Service and Repair Front Axle - C205F Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove half shaft from vehicle. 2. Remove skid plate, if equipped. 3. Clean axle seal area. 4. Remove axle shaft o-ring. 5. Remove axle shaft. 6. Remove axle shaft seal with a small pry bar. INSTALLATION 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8402 (1). 3. Install axle shaft and half shaft. Seal - Pinion SEAL-PINION REMOVAL 1. Remove both half shafts. 2. Remove front propeller shaft. 3. Rotate pinion gear three or four times and verify pinion rotates smoothly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4459 4. Record pinion rotating torque with an inch pound torque wrench (2), for installation reference. 5. Position Holder 6719 against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts. 6. Remove pinion nut. 7. Remove companion flange with (1) Remover C-452 (2). 8. Remove pinion seal with a pry tool or a slide hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install seal with Installer 8695 (2) and Handle C-4171 (1). 3. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4460 4. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange. 5. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to these instruction will damage the axle. 6. Record pinion rotating torque using an inch pound torque wrench (2). The rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). 7. If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until the proper rotating torque is achieved. CAUTION: If maximum tightening torque 475 Nm (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to these instruction will damage the axle. 8. Install propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4461 Seals and Gaskets: Service and Repair Front Axle - 9 1/4AA Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. 5. Install Receiver 8498 (1) into the adjuster bore. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4462 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and the axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut on the extractor rod and pull the seal out and into the receiver. INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seal are installed with the axle guide facing outward. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4463 2. Install Turnbuckle 8885-1 (2) into the installer cups and expand the turnbuckle until the seal bottom out in the housing. 3. Install differential into the axle housing. 4. Install axle shaft and hub bearings. Seal - Pinion SEAL-PINION REMOVAL 1. Mark the propeller shaft and pinion flange (1) for installation reference. 2. Remove propeller shaft. 3. Remove hub bearings and axle shafts. 4. Rotate pinion gear three or four times. 5. Measure and record the torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2) 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4464 INSTALLATION 1. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon thread sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange with Flange Wrench 8979 and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion rotating torque with an inch pound torque wrench and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion rotating torque again. 9. Install axle shafts and hub bearings. 10. Install propeller shaft with reference marks aligned. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4465 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a small pry bar. INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735-1. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Seal - Pinion SEAL-PINION REMOVAL 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4466 4. Rotate companion flange (1) three or four times and record pinion rotating torque with an inch pound torque wrench (2). 5. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 6. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 7. Remove companion flange with Remover C-452 (2). 8. Remove pinion seal with pry tool or slide-hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4467 2. Install new pinion seal with Installer C-3860-A (2) and Handle C-4171 (1). 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719 (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719 (2). 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Failure to follow these instructions will damage the collapsible spacer. 8. Hold companion flange with Holder 6719 (2) and tighten the pinion nut with a torque set to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4468 9. Rotate pinion with an inch pound torque wrench (2). Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low, use Holder 6719 to hold the companion flange (1) and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten the companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install brake rotors. 14. Check the differential lubricant level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4469 Seals and Gaskets: Service and Repair Rear Axle - 10 1/2AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Measure and record the amount of torque necessary to rotate the pinion gear (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 6. Remove pinion flange (1) with Flange Puller 8992 (2). 7. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4470 INSTALLATION 1. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1) 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) rotating torque with an inch pound torque wrench (2) and compare it to recorded measurement. 8. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 9. Rotate pinion several times then verify pinion rotating torque again. 10. Install axle shafts. 11. Install propeller shaft with reference marks aligned. 12. Check and fill differential if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4471 Seals and Gaskets: Service and Repair Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove half shaft from vehicle. 2. Remove skid plate, if equipped. 3. Clean axle seal area. 4. Remove axle shaft o-ring. 5. Remove axle shaft. 6. Remove axle shaft seal with a small pry bar. INSTALLATION 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8402 (1). 3. Install axle shaft and half shaft. Seal - Pinion SEAL-PINION REMOVAL 1. Remove both half shafts. 2. Remove front propeller shaft. 3. Rotate pinion gear three or four times and verify pinion rotates smoothly. 4. Record pinion rotating torque with an inch pound torque wrench (2), for installation reference. 5. Position Holder 6719 against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4472 6. Remove pinion nut. 7. Remove companion flange with (1) Remover C-452 (2). 8. Remove pinion seal with a pry tool or a slide hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install seal with Installer 8695 (2) and Handle C-4171 (1). 3. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A. 4. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4473 holder is held to the flange. 5. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to these instruction will damage the axle. 6. Record pinion rotating torque using an inch pound torque wrench (2). The rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). 7. If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until the proper rotating torque is achieved. CAUTION: If maximum tightening torque 475 Nm (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to these instruction will damage the axle. 8. Install propeller shaft. Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4474 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and the axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut on the extractor rod and pull the seal out and into the receiver. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4475 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seal are installed with the axle guide facing outward. 2. Install Turnbuckle 8885-1 (2) into the installer cups and expand the turnbuckle until the seal bottom out in the housing. 3. Install differential into the axle housing. 4. Install axle shaft and hub bearings. Seal - Pinion SEAL-PINION REMOVAL 1. Mark the propeller shaft and pinion flange (1) for installation reference. 2. Remove propeller shaft. 3. Remove hub bearings and axle shafts. 4. Rotate pinion gear three or four times. 5. Measure and record the torque necessary to rotate the pinion gear with an inch pound torque wrench (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4476 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2) 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. INSTALLATION 1. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon thread sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange with Flange Wrench 8979 and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion rotating torque with an inch pound torque wrench and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion rotating torque again. 9. Install axle shafts and hub bearings. 10. Install propeller shaft with reference marks aligned. Seal - Axle Shaft SEAL-AXLE SHAFT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4477 REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a small pry bar. INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735-1. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Seal - Pinion SEAL-PINION REMOVAL 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4478 4. Rotate companion flange (1) three or four times and record pinion rotating torque with an inch pound torque wrench (2). 5. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 6. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 7. Remove companion flange with Remover C-452 (2). 8. Remove pinion seal with pry tool or slide-hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4479 2. Install new pinion seal with Installer C-3860-A (2) and Handle C-4171 (1). 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719 (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719 (2). 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Failure to follow these instructions will damage the collapsible spacer. 8. Hold companion flange with Holder 6719 (2) and tighten the pinion nut with a torque set to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated. 9. Rotate pinion with an inch pound torque wrench (2). Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low, use Holder 6719 to hold the companion flange (1) and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4480 NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten the companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install brake rotors. 14. Check the differential lubricant level. Rear Axle - 10 1/2AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Measure and record the amount of torque necessary to rotate the pinion gear (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4481 6. Remove pinion flange (1) with Flange Puller 8992 (2). 7. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. INSTALLATION 1. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1) 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4482 7. Measure pinion (1) rotating torque with an inch pound torque wrench (2) and compare it to recorded measurement. 8. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 9. Rotate pinion several times then verify pinion rotating torque again. 10. Install axle shafts. 11. Install propeller shaft with reference marks aligned. 12. Check and fill differential if necessary. Rear Axle - 11 1/2AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4483 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2) 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. INSTALLATION 1. Install new pinion seal with Handle C-4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4484 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) rotating torque with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion rotating torque again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove axle shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4485 2. Remove axle shaft seal (1) from the end of the axle tube (2) with a pry bar. INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Coat new seal lip with axle lubricant and install seal with Installer 9343 (1) and Handle C-4171(2). 3. Install axle shaft. Seal - Pinion SEAL-PINION REMOVAL 1. Remove propeller shaft. 2. Remove brake calipers to prevent any drag. 3. Rotate pinion yoke three or four times. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4486 4. Record pinion gear (2) rotating torque with an inch pound torque wrench (1). 5. Hold yoke with Yoke Holder 6719A and remove pinion shaft nut and washer. 6. Remove pinion yoke (1) with Remover C-452 (2). 7. Remove pinion seal with pry tool or slide-hammer mounted screw. INSTALLATION 1. Coat lip of pinion seal with gear lubricant. 2. Install new pinion seal with Installer 9348 (2) and Handle C-4171 (1). 3. Install yoke on pinion shaft with Installer C-3718 and Yoke Holder 6719A. 4. Install pinion yoke washer with the concave surface against the yoke end. 5. Install new pinion nut. CAUTION: Never exceed minimum tightening torque when installing the pinion yoke retaining nut at this point. Failure to heed caution may result in damage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 4487 6. Hold pinion yoke with Yoke Holder 6719A (2) and tighten nut with torque wrench (3) to 292 Nm (215 ft. lbs.). Rotate pinion shaft several revolutions to ensure bearing rollers are seated. 7. Rotate pinion (2) with a inch pound torque wrench (1). Rotating torque should be equal to reading recorded during removal, plus 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instruction will result in damage. 8. If rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. 9. Install brake components. 10. Install propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations > Page 4492 Switch-Axle Lock (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 Axle Bearing: Service and Repair Rear Axle - 9 1/4 BEARING-AXLE REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove axle shaft bearing with Bearing Remover 6310 (2) (3) (4) (5) and Foot 6310-9 (7). INSTALLATION 1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735-1. 4. Install the axle shaft (1). 5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4498 Axle Bearing: Service and Repair Rear Axle - 10 1/2 AA BEARING-AXLE HUB REMOVAL 1. Remove axle shaft flange bolts and remove axle shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4499 6. Pry out hub bearing seal from the back of the hub. NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed. 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8962 and Handle C-4171. 3. Pack bearings with the appropriate grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. End play should be 0.025 - 0.25 mm (0.001 - 0.010 inch). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4500 8. Install retainer ring (1) with ring end in the key slot. 9. Install new axle shaft gasket and install axle shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4501 Axle Bearing: Service and Repair Rear Axle - 11 1/2 AA BEARING-AXLE HUB REMOVAL 1. Remove axle shaft flange bolts and remove shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4502 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed. 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8153 and Handle C-4171. 3. Pack bearings with the appropriate wheel bearing grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: End play should be 0.025 - 0.25 mm (0.01 - 0.001 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4503 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install the axle shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4504 Axle Bearing: Service and Repair Rear Axle - 248RBI BEARING-AXLE REMOVAL 1. Remove axle shaft. 2. Remove axle seal with pry bar. 3. Position bearing (2) Receiver 9345 (1) on axle tube. 4. Insert bearing Remover 6310 with Foot 6310-9 (3) through receiver (2) and bearing (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 4505 5. Tighten Remove 6310 nut (1) to pull bearing (3) into the receiver (3). INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Install axle shaft bearing with Installer 9344 (1) and Handle C-4171 (2). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat new axle seal lip with axle lubricant and install with Installer 9343 and Handle C-4171. 4. Install axle shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference Axle Shaft: Service and Repair Dana Axle Number Cross Reference New Model Number ............................................................................................................................. ..................................... Old Dana Model Number 174 ....................................................................................................................................................... .......................................................................... 28 181 ....................................................................... .......................................................................................................................................................... 30 186 .................................................................................................................................................. .................................................................... Super 30 194 .................................................................. .............................................................................................................................................................. . 35 198 ................................................................................................................................................ ...................................................................... Super 35 200 ................................................................ .............................................................................................................................................................. ... 36 216 .............................................................................................................................................. ................................................................................... 44 226 .............................................................. ........................................................................................................................................................ Super 44 229 ....................................................................................................................................... .......................................................................................... 50 248 ....................................................... .............................................................................................................................................................. ............ 60 267 ..................................................................................................................................... ............................................................................................ 70 286 ..................................................... .............................................................................................................................................................. .............. 80 First Letter of Suffix F .......................................................................................................................................................... ................................................................ Front R ................................................................................ ........................................................................................................................................... Rear Second Letter of Suffix B .......................................................................................................................................................... ................................................................ Beam I ................................................................................ ................................................................................................................................ Independent Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4511 Third Letter of Suffix I ............................................................................................................................................................ ................................................................. Iron A ................................................................................. ................................................................................................................................. Aluminum Examples: 248FBI ................................................................................................................................................. ................... Dana 60, Front, Beam Axle, Iron 186FIA .............................................................................................................................................. Dana Super 30, Front, Independent, Aluminum 226RBA ............................................................................................................................................... Dana Super 44, Rear, Beam Axle, Aluminum Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4512 Axle Shaft: Service and Repair Front Axle - 9 1/4 SHAFT-AXLE REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped. 3. Remove axle shaft (2) cotter pin (3), hub nut (1) and washer. 4. Remove four hub bearing bolts (2) from the back of the steering knuckle. 5. Remove hub bearing from the steering knuckle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4513 6. Remove axle shaft (2) from steering knuckle (1) and axle housing. DISASSEMBLY Single cardan U-Joint components are not serviceable. If defective they must be replaced as a unit. CAUTION: Clamp only the narrow forged portion of the yoke in the vise. Failure to follow these instructions will damage the yoke. 1. Remove the bearing cap (7) retaining snap rings (8). NOTE: Saturate the bearing caps with penetrating oil prior to removal. 2. Locate a socket (1) with an inside diameter that is larger than the bearing cap. Place the socket (receiver) against the yoke and around the perimeter of the bearing cap to be removed. 3. Locate a socket (3) with an outside diameter that is smaller than the bearing cap. Place the socket (driver) against the opposite bearing cap. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4514 4. Position the yoke with the sockets in a vise (2). 5. Tighten the vise jaws to force the bearing cap into the larger socket (receiver). 6. Release the vise jaws. Remove the sockets and bearing cap that was partially forced out of the yoke. 7. Repeat the above procedure for the remaining bearing cap and remove spider from the propeller shaft yoke. ASSEMBLY 1. Pack the bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium base lubricant to aid in installation. 2. Position the spider in the yoke (1). Insert the seals and bearings. Tap the bearing caps into the yoke bores far enough to hold the spider in position. 3. Place the socket (driver) against one bearing cap. Position the yoke with the socket in a vise. 4. Tighten the vise to force the bearing caps into the yoke. Force the caps enough to install the retaining clips. 5. Install the bearing cap retaining clips. 6. Install axle shaft. INSTALLATION 1. Clean axle shaft and apply a thin film of Mopar Wheel Bearing Grease to the shaft splines and hub bore. 2. Install axle shaft (2) through the steering knuckle and into the differential side gears. 3. Install hub bearing in the knuckle (3). 4. Install hub bearing bolts and tighten to 202 Nm (149 ft. lbs.). 5. Install ABS wheel speed sensor, brake rotor and caliper. 6. Install axle washer and nut. Tighten axle nut to 179 Nm (132 ft. lbs.). 7. Rotate axle several 5 to 10 times to seat the wheel bearing. 8. Tighten axle nut to final torque of 356 Nm (263 ft. lbs.). 9. Align nut to next cotter pin hole and install new cotter pin. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4515 Axle Shaft: Service and Repair Rear Axle - 10 1/2 AA SHAFT-AXLE REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. INSTALLATION NOTE: Axle flange bolts must be replaced or cleaned existing bolts apply Mopar Lock N' Seal or Loctite (R) 242 on the threads. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4516 Axle Shaft: Service and Repair Rear Axle - 11 1/2 AA SHAFT-AXLE REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. INSTALLATION NOTE: Axle flange bolts must be replaced or use Mopar Lock N' Seal or Loctite (R) 242 on cleaned existing bolts. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer Constant Velocity Joint: Service and Repair CV Joint-Outer CV JOINT-OUTER REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support CV joint. CAUTION: Do not damage CV housing or half shaft. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the CV joint snap ring (1). 5. Spread snap ring (1) and slide the joint off the shaft. 6. Slide boot off the shaft and discard old boot. 7. Mark alignment marks (1) on the inner race/hub (2), bearing cage (3) and housing with dabs of paint. 8. Clamp ON joint in a vertical position in a soft jawed vise. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 4521 9. Press down one side of the bearing cage (3) to gain access to the ball at the opposite side. NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift. 10. Remove ball (4) from the bearing cage (3). 11. Repeat step above until all six balls are removed from the bearing cage. 12. Lift cage and inner race (2) upward and out from the housing (1). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage. INSTALLATION NOTE: If CV joint is worn, replace entire CV joint and boot. 1. Clean all CV joint components and shaft. 2. Apply a light coat of grease supplied with the joins boot to the CV joint components before assembling them. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 4522 3. Align the inner race (1) cage (2) and housing according to the alignment reference marks. 4. Insert the inner race (1) into the cage (2) and rotate race into the cage. 5. Rotate the inner race/hub (2) in the cage. 6. Insert cage (2) into the housing. Rotate the cage 90° into the housing (3) so the large bearing hub counterbore is facing outwards. 7. Apply the grease supplied with the joint/boot to the ball races. Spread the grease equally between all the races. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 4523 8. Tilt inner race/hub (1) and cage (3) and install the balls(4). 9. Place new clamps onto new boot and slide boot onto the shaft to it's original position. 10. Apply the rest of grease to the CV joint and boot. 11. Install the joint onto the shaft (2). Push the joint onto the shaft until the snap ring (1) seats in the groove (3). NOTE: Pull on the joint to verify the span ring has engaged. 12. Position the boot on the joint in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 13. Secure both boot (5) clamps (2) (4) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until jaws of the tool are closed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 4524 Constant Velocity Joint: Service and Repair CV Joint-Inner CV JOINT-INNER REMOVAL 1. Clamp shaft in vise (with soft jaws) and support CV joint. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. CAUTION: Do not damage CV housing or half shaft with cut-off wheel or grinder. 3. Remove housing (1) from the half shaft and slide boot (2) down shaft. 4. Remove housing bushing from the housing. 5. Remove tripod (2) snap ring (1). 6. Remove tripod (2) and boot from the half shaft. 7. Clean and inspect CV components for excessive wear and damage. Replace the tripod as a unit only if necessary. INSTALLATION 1. Clean all CV joint components and shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 4525 2. Slide new boot (1) down the half shaft. 3. Install tripod (2) and tripod snap ring on the half shaft. 4. Pack grease supplied with the joint/boot into the housing and boot. 5. Coat tripod with supplied grease. 6. Install new bushing (1) onto the housing (2). 7. Insert the tripod and shaft in the housing. 8. Position the boot (2) on the housing (5) and shaft (4) in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 9. Measure the distance from the end of the housing to the end of the boot on the shaft. This measurement should be 260 mm (10.25 inch). NOTE: If measurement is not correct, allow more or less air into the boot. 10. Secure both boot clamps (1) (3) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4529 Wheel Bearing: Service and Repair HUB/BEARING - 4X4 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using special tool 8677. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using special tool 8677. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. 9. Remove the support and lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair BEARING-CENTER REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference mark (1) on the two shafts. 3. Remove slip joint boot (4) clamp (3) and separate the two shafts. 4. Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. 5. Position Bearing Splitter Tool 1130 between slinger and shaft. CAUTION: Do not damage shaft spline during removal of center bearing. 6. Set shaft in press and press bearing off the shaft. INSTALLATION NOTE: Two types of center bearings are used and are not interchangeable. Install the same type as the vehicle was built with. 1. Install new slinger on shaft and drive into position with appropriate installer tool. 2. Install new center bearing (2) on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer until bearing is seated. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot (4) and install new clamp (3). 5. Install propeller shaft in vehicle. ADJUSTMENTS Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4541 Drive/Propeller Shaft: Testing and Inspection PROPELLER SHAFT VIBRATION Out-of-round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. DRIVELINE VIBRATION PROPELLER SHAFT BALANCE If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180° relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. 6. Remove wheels and install lug nuts to retain brake rotors. 7. Mark and number the shaft six inches from the pinion yoke end at four positions 90° apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4542 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4543 PROPELLER SHAFT RUNOUT 1. Clean propeller shaft surface, where dial indicator will contact the shaft. 2. Install dial indicator perpendicular to the shaft surface. 3. Measure runout at the center and ends of the shaft away from weld areas, so weld process does not affect measurements. 4. Refer to Runout Specifications chart. 5. If runout is out of specification, index the shaft 180° and take shaft runout measurements again. 6. If runout is now within specifications, mark shaft and yokes for proper orientation. 7. If runout is not within specifications, verify runout of the transmission/transfer case and axle are within specifications. Correct as necessary and measure propeller shaft runout again. 8. Replace propeller shaft if the runout still exceeds the limits. RUNOUT SPECIFICATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle Drive/Propeller Shaft: Service and Repair Propeller Shaft Angle PROPELLER SHAFT ANGLE TWO PIECE PROPELLER SHAFT Two piece propeller shaft angles measurement is the same as a one-piece propeller shaft. ONE PIECE PROPELLER SHAFT This procedure applies to front and rear propeller shafts. NOTE: To obtain output angle (A) on the front propeller shaft equipped with a ON joint, place inclinometer on machined surface of the ON joint. 1. Raise vehicle and support the axles as level as possible, allowing the wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base sits flat. 3. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission yoke Output Angle (A). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4546 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the Propeller Shaft Angle (C). 6. Rotate propeller shaft 90 degrees and place inclinometer on companion flange yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement will give you the pinion Companion Flange Input Angle (B). 7. Subtract smaller figure from larger (C minus A) to obtain Transmission/Transfer Case Output Operating Angle. 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules and example in for additional information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4547 RULES ^ Good cancellation of U-Joint operating angles should be within 1 degree. ^ Operating angles should be less than 3 degrees. ^ Operating angles less than 10 degrees for double cardan U-Joint. ^ At least 1/2 of one degree continuous operating propeller shaft angle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4548 Drive/Propeller Shaft: Service and Repair Shaft-Propeller LD Front SHAFT-PROPELLER LD FRONT REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove exhaust crossover pipe. 3. Mark a line across the axle companion flange (1), propeller shaft (2), flange yoke (3) and transfer case for installation reference. 4. Remove axle/transfer case companion flange bolts. Remove dust boot clamp (3) from the C/V joint (1) end of the shaft if equipped. 5. Remove propeller shaft. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4549 1. Install propeller shaft with all reference marks (4) aligned. 2. Install with dust boot clamp at transfer case end. 3. Install new axle companion flange bolts and tighten to 115 Nm (85 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite (R) 242 to the threads. 4. Install skid plate, if equipped. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4550 Drive/Propeller Shaft: Service and Repair Shaft-Propeller HD Front SHAFT-PROPELLER HD FRONT REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove exhaust crossover pipe. 3. Mark a line across axle (3)/transfer case (2) companion flange and propeller shaft flange yokes for installation reference. 4. Remove axle/transfer case companion flange bolts. 5. Remove propeller shaft. INSTALLATION 1. Install propeller shaft (1) with all reference marks aligned. 2. Install transfer case companion flange (2) bolts and tighten to 88 Nm (65 ft. lbs.). 3. Install new axle companion flange (3) bolts and tighten to 28 Nm (21 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite (R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite (R) 242 to the threads. 4. Install skid plate, if equipped. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4551 Drive/Propeller Shaft: Service and Repair Shaft-Propeller Rear SHAFT-PROPELLER REAR REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark pinion flange (3) or yoke and propeller shaft (1) flange (4) or yoke for installation reference. 3. Mark the outline of the center bearing (1) on the crossmember for installation reference, if equipped. 4. Remove center bearing mounting nuts (3), if equipped. 5. Remove pinion flange or yoke clamp bolts. 6. Slide propeller shaft back on transmission then mark the shaft and transmission for installation reference. 7. Remove propeller shaft from transmission/transfer case. INSTALLATION 1. Slide slip yoke onto the transmission/transfer case output shaft with reference marks aligned. 2. Align and install center bearing on crossmember, if equipped and tighten nuts to 54 Nm (40 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4552 3. Align reference marks on propeller shaft (2) and pinion flange or pinion yoke. 4. Install new companion flange (1) bolts and tighten to 15 Nm (85 ft. lbs.) 5. Install new SRT-10 yoke clamp (4) bolts and tighten to 29 Nm (22 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite (R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite (R) 242 to the threads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 4553 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint: Service and Repair Single Cardan With Injected Ring DISASSEMBLY - WITH INJECTED RING 1. Place shaft yoke in vise. 2. Position U-Joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-Joint bearing caps (1) out of shaft yoke (2). 4. Remove lower bearing cap from shaft yoke. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4558 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-Joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-Joint out of shaft yoke (2). 8. Position U-Joint press (2) with receiver (1) on flange. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4559 9. Press U-Joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-Joint press (2) with receiver (1) on flange. 12. Press remaining U-Joint bearing cap out of flange. 13. Remove U-Joint from flange. ASSEMBLY NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4560 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). 4. Install snap ring (2) on bearing (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4561 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). 8. Install flange (1) with U-Joint in yoke (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4562 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4563 14. Install snap ring (2) on bearing cap (1). With Snap Rings DISASSEMBLY - WITH SNAP RINGS 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. 3. Position yoke with the grease fitting if equipped, pointing up. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4564 4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke with lube fitting pointing up, if equipped. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4565 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat Step 3 and Step 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. 7. Install propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4566 Universal Joint: Service and Repair Double Cardan DISASSEMBLY 1. Remove propeller shaft. 2. Mark propeller shaft, link yoke and flange yoke for assembly reference. 3. Tap outside of the bearing cap assembly with drift to loosen snap rings. 4. Remove all bearing cap snap rings. 5. Remove grease fittings if equipped. 6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke. 7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. 8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4567 9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap. 10. Flip assembly and repeat Step 6, Step 7, Step 8 and Step 9 to remove the opposite bearing cap. 11. Remove cross centering kit assembly and spring. 12. Press remaining bearing caps out the other end of the link yoke. ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Fit cross into the propeller shaft yoke. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4568 3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap. 4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring. 5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4569 6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings. 7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned. 8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 4570 9. Press remaining two bearing caps into place and install snap rings. 10. Tap snap rings to seat them into the grooves. 11. Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled. 12. Install propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications For automatic transmissions: Tighten the flexplate retaining bolts to ......................................................................................................................................... 95 Nm (70 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4574 Flex Plate: Service and Repair FLEX PLATE REMOVAL 1. Remove the transmission. 2. Remove the bolts and flexplate (1). INSTALLATION 1. Position the flexplate or flywheel onto the crankshaft and install the bolts hand tight. 2. For automatic transmissions: Tighten the flexplate retaining bolts to 95 Nm (70 ft. lbs.). 3. Install the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection Flywheel: Testing and Inspection FLYWHEEL Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 inch). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a stud installed in place of one of the flywheel bolts. Common causes of runout are: ^ heat warpage ^ improper machining ^ incorrect bolt tightening ^ improper seating on crankshaft flange shoulder ^ foreign material on crankshaft flange Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with surface grinding equipment. Remove only enough material to reduce scoring ( approximately 0.001 - 0.003 inch). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 inch). Excessive stock removal can result in flywheel cracking or warpage after installation; it can also weaken the flywheel and interfere with proper clutch release. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Page 4578 Flywheel: Service and Repair FLYWHEEL REMOVAL 1. Remove transmission. 2. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 3. Remove bolts completely and remove pressure plate and disc. 4. Remove flywheel bolts and remove flywheel. NOTE: Vehicles with Dual Mass Flywheel use an adapter plate between the flywheel and crank. This plate does not need to be removed. INSTALLATION 1. Install flywheel on the crankshaft or adapter plate if vehicle has Dual Mass flywheel. 2. Install flywheel bolts and tighten to 95 Nm (70 ft. lbs.). Vehicles with Dual Mass Flywheel, tighten adapter plate bolts to 55 Nm (40 ft. lbs.) 3. Install clutch. 4. Install transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The tow/haul indicator consists of the text "TOW/HAUL", which appears in the lower portion of the odometer/trip odometer indicator Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "TOW/ HAUL" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The tow/haul indicator is serviced as a unit with the VFD in the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the Off position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tow/haul indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the Off position of the tow/haul switch has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The transmission over-temperature indicator consists of a stencil-like cutout of the text "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED. For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation Four Wheel Drive Indicator Lamp: Description and Operation A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The service 4WD indicator consists of the text "SERV 4WD", which appears in the lower portion of the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "SERV 4WD" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the VFD in the instrument cluster. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TCCM over the Programmable Communications Interface (PCI) data bus. The service 4WD indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the service 4WD indicator for the following reasons: - Service 4WD Lamp-On Message - Each time the cluster receives a service 4WD lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-off message from the TCCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for five seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection Bell Housing: Testing and Inspection CLUTCH HOUSING The clutch housing maintains alignment between the crankshaft and transmission input shaft. Misalignment can cause clutch noise, hard shifting, incomplete release and chatter. Also premature pilot bearing, cover release fingers and clutch disc wear. In severe cases, it can cause premature wear of the transmission input shaft and front bearing. NOTE: Only the NV4500 clutch housing can be checked using the following bore and face runout procedures. The NV5600 clutch housing is a integral part of the transmission and can only be checked off the vehicle. CLUTCH HOUSING BORE RUNOUT CAUTION: On diesel engines if housing bore runout exceeds 0.015 inch, the clutch housing/transmission adapter plate must be replaced. On gas engines if housing bore runout exceeds 0.053 inch the clutch housing must be replaced. NOTE: Offset dowels are available for gas engines to correct housing bore runout. They are not available for diesel engines. 1. Remove the clutch housing. 2. Remove the clutch cover and disc. 3. Replace one of the flywheel bolts with an appropriate size threaded rod (3) that is 10 inch (25.4 cm) long. The rod will be used to mount the dial indicator. 4. Remove release fork from the clutch housing. 5. Install clutch housing. Tighten the housing bolts nearest the alignment dowels first. 6. Mount dial indicator (2) on the threaded rod (1) and position indicator plunger (3) on the clutch housing bore (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 4601 7. Rotate crankshaft until indicator plunger is at the top of the housing bore (1). Zero the indicator at this point. 8. Rotate crankshaft and record indicator readings at eight points (45° apart) around the bore. Take measurement at least twice for accuracy. 9. Subtract each reading from the one 180° opposite to determine runout and direction. Bore runout example: ^ 0.000 - (-0.007) = 0.007 inch ^ +0.002 - (-0.010) = 0.012 inch ^ +0.004 - (-0.005) = 0.009 inch ^ -0.001 - (+0.001) = -0.002 inch In this example the largest or Total Indicator Reading (TIR) difference is 0.012 inch. This means the housing bore is offset from the crankshaft centerline by 0.006 inch which is 1/2 of 0.012 inch. The dowels (2) needed to correct this have an offset of 0.007 inch. Remove housing and install dowels with the slotted side facing out so they can be turned with a screwdriver. Then install the housing and mount the dial indicator and check bore runout again. Rotate the dowels until the TIR is less than 0.010 inch. Clutch Housing Face Runout 1. Position dial indicator (2) towards the housing face with indicator plunger (1) on the rim of the housing bore. 2. Rotate crankshaft until indicator plunger is at the 10 O'clock position and zero the dial indicator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 4602 3. Measure and record face runout (1) readings at four points 90° apart. Take measurement at least twice for accuracy. 4. Subtract lowest reading from highest to determine total runout. If low reading was minus 0.004 inch and highest reading was plus 0.009 inch the total runout is 0.013 inch. NOTE: Maximum acceptable face runout is 0.010 inch. To correct this example the shims needed between the clutch housing and transmission are: ^ 0.009 inch at the 0.000 corner ^ 0.012 inch at the -0.003 corner ^ 0.013 inch at the -0.004 corner After installing the clutch assembly and housing, tighten the housing bolts nearest the alignment dowels first. NOTE: Shims can be made from shim stock or similar materials of the required thickness. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 4603 Bell Housing: Service and Repair CLUTCH HOUSING REMOVAL 1. Remove transmission (2) and transfer case. 2. Remove starter from clutch housing. 3. Remove structural dust cover bolts from clutch housing. CAUTION: Do not remove structural dust cover from engine block. If cover is removed clutch housing and cover must be aligned with the engine. 4. Remove clutch housing (1) bolts and remove housing from the engine. INSTALLATION 1. Clean housing mounting surface of engine block (1) with wax and grease remover. 2. Verify that clutch housing alignment dowels are in good condition and properly seated. 3. Transfer slave cylinder, release fork and boot, fork pivot stud and wire/hose brackets to new housing (3). 4. Install structural dust cover (4) if removed. 5. Align and install clutch housing (3) on engine (1). Tighten housing bolts across the top of the housing first and to the following torque values: ^ "A" bolts 1/4in. diameter - 4.5 Nm (40 inch lbs.) ^ "A" bolts 3/8in. diameter - 40 Nm (30 ft. lbs.) ^ "A" bolts 7/16in. diameter - 68 Nm (50 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 4604 ^ "B" bolts for 5.7L 5.9L TD/8.0L engines - 47.5 Nm (40 ft. lbs.) ^ "C" bolts for 5.7L engine - 68 Nm (50 ft. lbs.) ^ "C" bolts for 5.9L TD engine - 47.5 Nm (35 ft. lbs.) ^ "C" bolts for 8.0L engine - 74.5 Nm (55 ft. lbs.) 6. Install starter to clutch housing. 7. Install transmission and transfer case, if equipped. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4610 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4615 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications DIESEL ENGINE - G56 ....................................................................................................................... ........................................................ 12 pts. (5.67 L) 5.7L ENGINE - G56 ............................................................................................................................. .......................................................... 10 pts. (4.7 L) GETRAG 238 ...................................................................................................................................... ........................................................... 4.2 pts. (2.2 L) NV5600 ................................................................................................................................................ ........................................................ 9.5 pts. (4.50 L) NV4500 ................................................................................................................................................ ........................................................ 8.0 pts. (3.79 L) TREMEC T-56 ..................................................................................................................................... ......................................................... 4.8 pts. (2.27 L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4618 Fluid - M/T: Fluid Type Specifications NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. NV5600 ................................................................................................................................................ ................... Mopar Manual Transmission Lubricant NV4500 ...................................................................................................................................... Mopar Synthetic 75W-85 Manual Transmission Lubricant Getrag 238 ........................................................................................................................................... ..................... Mopar ATF+4 Transmission Lubricant G 56 ..................................................................................................................................................... ..................... Mopar ATF+4 Transmission Lubricant Tremec T56 ................................................................................................................................ Mopar Synthetic 75W-85 Manual Transmission Lubricant Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and Operation Power Take-Off: Description and Operation This Powertrain Control Module (PCM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. The input is used only to tell the PCM (or ECM-Diesel) that the PTO has been engaged. The PCM (or ECM) will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO is engaged. JTEC and NGC Engine Controllers: When the aftermarket PTO switch has been engaged, a 12V + signal is sent through circuit G113 to PCM pin A13. The PCM will then sense and determine that the PTO has been activated. CM 845 or CM 848 Diesel Engine Controllers: When the aftermarket PTO switch has been engaged, a 12V + signal is sent through circuit G113 to ECM pin B38. The ECM will then sense and determine that the PTO has been activated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4627 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4628 In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4629 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 4657 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4662 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4663 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4664 Control Module: Diagrams Module-Final Drive Control (Off Road) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4665 Module-Transfer Case Control C1 (Electronic 4x4) Module-Transfer Case Control C2 (Electric 4x4) Module-Transfer Case Control C3 (Electric 4x4) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4666 Control Module: Description and Operation The Transfer Case Control Module (TCCM) (2) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel (1). The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4667 - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for atleast 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4668 - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 ± seconds 100 msec. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel, (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds ± 50 msec . and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4669 following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4675 Sensor-Line Pressure (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4676 Fluid Pressure Sensor/Switch: Description and Operation SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4677 Fluid Pressure Sensor/Switch: Service and Repair SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4681 Switch-Tow/Haul Overdrive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4682 Overdrive Switch: Description and Operation SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4683 Overdrive Switch: Service and Repair SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4684 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4691 Transmission Speed Sensor: Diagrams Sensor-Input Speed (RFE) Sensor-Output Speed (RFE) Sensor-Output Speed (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed Transmission Speed Sensor: Description and Operation Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: . Torque converter clutch slippage . Torque converter element speed ratio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed > Page 4694 Transmission Speed Sensor: Description and Operation Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed Transmission Speed Sensor: Service and Repair Sensor-Input Speed Sensor-Input Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed > Page 4697 Transmission Speed Sensor: Service and Repair Sensor-Output Speed Sensor-Output Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Sensor-Transmission Range (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 4701 Transmission Temperature Sensor/Switch: Description and Operation SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations > Page 4706 Switch-Axle Lock (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4711 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4712 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4713 Switch-Transfer Case Selector (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Four Wheel Drive Selector Switch: Description and Operation NV243 SWITCH-SELECTOR DESCRIPTION The selector switch assembly (1) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: ^ the 2WD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 4716 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 4717 Four Wheel Drive Selector Switch: Description and Operation NV244 GenII SWITCH-TRANSFER CASE SELECTOR DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: ^ the AWD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Gear Sensor/Switch: Locations Left Transmission (RFE) Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4721 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4722 Gear Sensor/Switch: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Sensor-Transfer Case Position (MTC Except Power Wagon) Sensor-Transfer Case Position (MTC Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 Gear Sensor/Switch: Description and Operation NV243 Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4725 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4726 Gear Sensor/Switch: Description and Operation NV244 GenII Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4727 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 Gear Sensor/Switch: Service and Repair NV243 ASSEMBLY-SHIFT MOTOR/MODE SENSOR REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 > Page 4730 Gear Sensor/Switch: Service and Repair NV244 GenII REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4736 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4737 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4738 Transfer Case Actuator: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4742 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4743 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4744 Control Module: Diagrams Module-Final Drive Control (Off Road) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4745 Module-Transfer Case Control C1 (Electronic 4x4) Module-Transfer Case Control C2 (Electric 4x4) Module-Transfer Case Control C3 (Electric 4x4) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4746 Control Module: Description and Operation The Transfer Case Control Module (TCCM) (2) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel (1). The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4747 - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for atleast 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4748 - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 ± seconds 100 msec. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel, (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds ± 50 msec . and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4749 following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4755 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4760 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV241 GEN II ...................................................................................................................................... ................................................. 1.6 Liters (3.4 pts.) NV243 .................................................................................................................................................. .................................................. 1.6 Liters (3.4 pts.) NV241 GEN II ...................................................................................................................................... ................................................. 1.6 Liters (3.4 pts.) NV271 .................................................................................................................................................. ................................................ 1.89 Liters (4.0 pts.) NV273 .................................................................................................................................................. ................................................ 1.89 Liters (4.0 pts.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4763 Fluid - Transfer Case: Fluid Type Specifications Fluid Type ................................................................................................................................................... Mopar ATF +4 Automatic Transmission Fluid Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GenII Fluid - Transfer Case: Service and Repair NV241 GenII FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20 - 34 Nm (15 - 25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20 34 Nm (15 - 25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GenII > Page 4766 Fluid - Transfer Case: Service and Repair NV243 FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20 34 Nm (15 - 25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GenII > Page 4767 Fluid - Transfer Case: Service and Repair NV244 GenII FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20 - 34 Nm (15 - 25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20 - 34 Nm (15 - 25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation Four Wheel Drive Indicator Lamp: Description and Operation A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The service 4WD indicator consists of the text "SERV 4WD", which appears in the lower portion of the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "SERV 4WD" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the VFD in the instrument cluster. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TCCM over the Programmable Communications Interface (PCI) data bus. The service 4WD indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the service 4WD indicator for the following reasons: - Service 4WD Lamp-On Message - Each time the cluster receives a service 4WD lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-off message from the TCCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for five seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4774 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4775 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4776 Switch-Transfer Case Selector (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Four Wheel Drive Selector Switch: Description and Operation NV243 SWITCH-SELECTOR DESCRIPTION The selector switch assembly (1) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: ^ the 2WD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 4779 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 4780 Four Wheel Drive Selector Switch: Description and Operation NV244 GenII SWITCH-TRANSFER CASE SELECTOR DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: ^ the AWD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Gear Sensor/Switch: Locations Left Transmission (RFE) Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4784 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4785 Gear Sensor/Switch: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Sensor-Transfer Case Position (MTC Except Power Wagon) Sensor-Transfer Case Position (MTC Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 Gear Sensor/Switch: Description and Operation NV243 Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4788 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4789 Gear Sensor/Switch: Description and Operation NV244 GenII Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4790 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 Gear Sensor/Switch: Service and Repair NV243 ASSEMBLY-SHIFT MOTOR/MODE SENSOR REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 > Page 4793 Gear Sensor/Switch: Service and Repair NV244 GenII REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation Four Wheel Drive Indicator Lamp: Description and Operation A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The service 4WD indicator consists of the text "SERV 4WD", which appears in the lower portion of the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "SERV 4WD" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the VFD in the instrument cluster. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TCCM over the Programmable Communications Interface (PCI) data bus. The service 4WD indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the service 4WD indicator for the following reasons: - Service 4WD Lamp-On Message - Each time the cluster receives a service 4WD lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-off message from the TCCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for five seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4802 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4803 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4804 Control Module: Diagrams Module-Final Drive Control (Off Road) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4805 Module-Transfer Case Control C1 (Electronic 4x4) Module-Transfer Case Control C2 (Electric 4x4) Module-Transfer Case Control C3 (Electric 4x4) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4806 Control Module: Description and Operation The Transfer Case Control Module (TCCM) (2) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel (1). The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4807 - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for atleast 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4808 - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 ± seconds 100 msec. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel, (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds ± 50 msec . and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4809 following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GenII Seals and Gaskets: Service and Repair NV241 GenII Seal-Extension Housing SEAL-EXTENSION HOUSING REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw. remove the extension housing seal. INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Installer D-163 (2) and Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Front Output Shaft Seal FRONT OUTPUT SHAFT SEAL REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GenII > Page 4814 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. INSTALLATION 1. Install the new front output shaft seal with Installer MB991168A. 2. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A. 5. Install front propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GenII > Page 4815 Seals and Gaskets: Service and Repair NV243 Seal-Extension Housing SEAL-EXTENSION HOUSING REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Installer D-163 (2) and Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Seal-Front Output Shaft SEAL-FRONT OUTPUT SHAFT REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GenII > Page 4816 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. INSTALLATION 1. Install the new front output shaft seal with Installer MB991168A. 2. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A. 5. Install front propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GenII > Page 4817 Seals and Gaskets: Service and Repair NV244 GenII Seal-Extension Housing SEAL-EXTENSION HOUSING REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Installer D-163 (2) and Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Seal-Front Output Shaft Removal SEAL-FRONT OUTPUT SHAFT REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot retaining clamp (2) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GenII > Page 4818 3. Remove the front propeller shaft seal boot (1) from the front output shaft seal slinger. 4. Remove the front output shaft seal slinger (1) by bending the slinger away (2) from the transfer case. 5. Using a suitable pry tool, remove the slinger from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. INSTALLATION 1. Install the new front output shaft seal with Installer MB991168A. 2. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A. 5. Install front propeller shaft. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4823 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4824 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4825 Switch-Transfer Case Selector (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Four Wheel Drive Selector Switch: Description and Operation NV243 SWITCH-SELECTOR DESCRIPTION The selector switch assembly (1) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: ^ the 2WD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 4828 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 4829 Four Wheel Drive Selector Switch: Description and Operation NV244 GenII SWITCH-TRANSFER CASE SELECTOR DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: ^ the AWD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Gear Sensor/Switch: Locations Left Transmission (RFE) Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4833 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4834 Gear Sensor/Switch: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Sensor-Transfer Case Position (MTC Except Power Wagon) Sensor-Transfer Case Position (MTC Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 Gear Sensor/Switch: Description and Operation NV243 Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4837 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4838 Gear Sensor/Switch: Description and Operation NV244 GenII Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 4839 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 Gear Sensor/Switch: Service and Repair NV243 ASSEMBLY-SHIFT MOTOR/MODE SENSOR REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 > Page 4842 Gear Sensor/Switch: Service and Repair NV244 GenII REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Adjustments Shifter Transfer Case: Adjustments ADJUSTMENT- SHIFT LEVER 1. Move shift lever into 2H position. 2. Raise vehicle. 3. Loosen shift rod lock bolt at trunnion. 4. Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if necessary. 5. Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the transfer case shift arm is the second position from full forward. 6. Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly. 7. Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position. 8. Tighten shift rod lock bolt to 10 Nm (90 inch lbs.) torque. 9. Remove the locating pin from the adjustment channel and locating hole. 10. Check shift linkage operation. Be sure transfer case shifts into and operates properly in all ranges. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > Procedures Shifter Transfer Case: Procedures LEVER-SHIFT REMOVAL 1. Shift transfer case into 2H. 2. Raise and support the vehicle. 3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever. 4. Lower vehicle. 5. Remove transfer case shifter knob cap. 6. Remove nut holding shifter knob (2) to shift lever. 7. Remove shifter knob. 8. Remove the shift boot from the shifter console. 9. Remove the bolts securing the shifter mechanism to the floor pan. 10. Separate shift lever mechanism from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > Procedures > Page 4848 1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the position. 2. Position shift lever in vehicle. 3. Install the bolts to hold the shifter mechanism (4) to the floor pan. 4. Raise vehicle. 5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the second position from full forward. 6. Install trunnion to shift lever, if necessary. 7. Install shift rod to trunnion, if necessary. 8. Tighten the shift rod lock bolt to 10 Nm (90 inch lbs.). 9. Remove the shifter adjustment locating pin from the adjustment channel and the locating hole. 10. Lower vehicle. 11. Install the transfer case shifter console. 12. Install the shifter boot and the shifter knob onto the shifter lever. 13. Install nut to hold shifter knob to shift lever. 14. Install shifter knob cap. 15. Verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > Procedures > Page 4849 Shifter Transfer Case: Removal and Replacement 4WD FLOOR SHIFT BOOT REMOVAL 1. Using a small flat-bladed tool, remove the insert (2) from the top of the shift knob (1). 2. Remove the nut (3) that secures the shift knob to the gear shift lever. 3. Remove the gear shift knob (2). 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the gear shift boot (3) to the floor console (1) and remove the boot. INSTALLATION 1. Position the gear shift boot (3) over the gear shift lever. 2. Engage the retaining tabs that secure the gear shift boot to the floor console (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > Procedures > Page 4850 3. Install the shift knob (2) over the gear shift lever. 4. Install the nut (3) that secures the shift knob (1) to the gear shift lever. Tighten the nut to 27 N.m (20 ft.lbs.). 5. Install the insert (2) into the top of the shift knob. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4854 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4855 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4856 Transfer Case Actuator: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4863 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4864 Overdrive Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Page 4865 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4869 Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4870 Pressure Regulating Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4871 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4872 Pressure Regulating Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4873 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4877 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4878 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4879 Solenoid-Brake Transmission Shift Interlock Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4883 Shift Solenoid: Description and Operation ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4884 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4885 Shift Solenoid: Service and Repair Assembly-Transmission Solenoid/TRS REMOVAL 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4886 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams Torque Converter Clutch Solenoid: Diagrams Solenoid-Locker-Front (5.7L Off Road) Solenoid-Locker-Rear (Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations Starter Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4898 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4899 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 4900 Transfer Case Actuator: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The tow/haul indicator consists of the text "TOW/HAUL", which appears in the lower portion of the odometer/trip odometer indicator Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "TOW/ HAUL" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The tow/haul indicator is serviced as a unit with the VFD in the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the Off position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tow/haul indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the Off position of the tow/haul switch has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The transmission over-temperature indicator consists of a stencil-like cutout of the text "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED. For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation Four Wheel Drive Indicator Lamp: Description and Operation A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The service 4WD indicator consists of the text "SERV 4WD", which appears in the lower portion of the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "SERV 4WD" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the VFD in the instrument cluster. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TCCM over the Programmable Communications Interface (PCI) data bus. The service 4WD indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the service 4WD indicator for the following reasons: - Service 4WD Lamp-On Message - Each time the cluster receives a service 4WD lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-off message from the TCCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for five seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4924 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4925 In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4926 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 4954 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4959 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4960 Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4961 Control Module: Diagrams Module-Final Drive Control (Off Road) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4962 Module-Transfer Case Control C1 (Electronic 4x4) Module-Transfer Case Control C2 (Electric 4x4) Module-Transfer Case Control C3 (Electric 4x4) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4963 Control Module: Description and Operation The Transfer Case Control Module (TCCM) (2) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel (1). The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4964 - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for atleast 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4965 - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 ± seconds 100 msec. The TCCM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel, (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds ± 50 msec . and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4966 following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4972 Sensor-Line Pressure (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4973 Fluid Pressure Sensor/Switch: Description and Operation SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4974 Fluid Pressure Sensor/Switch: Service and Repair SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4978 Switch-Tow/Haul Overdrive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4979 Overdrive Switch: Description and Operation SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4980 Overdrive Switch: Service and Repair SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4981 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation Transmission Position Switch/Sensor: Description and Operation SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4988 Transmission Speed Sensor: Diagrams Sensor-Input Speed (RFE) Sensor-Output Speed (RFE) Sensor-Output Speed (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed Transmission Speed Sensor: Description and Operation Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: . Torque converter clutch slippage . Torque converter element speed ratio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Sensor-Input Speed > Page 4991 Transmission Speed Sensor: Description and Operation Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed Transmission Speed Sensor: Service and Repair Sensor-Input Speed Sensor-Input Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Sensor-Input Speed > Page 4994 Transmission Speed Sensor: Service and Repair Sensor-Output Speed Sensor-Output Speed REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Sensor-Transmission Range (RE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 4998 Transmission Temperature Sensor/Switch: Description and Operation SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Differential > Switch, Differential Lock > Component Information > Locations > Page 5003 Switch-Axle Lock (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5008 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5009 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5010 Switch-Transfer Case Selector (ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Four Wheel Drive Selector Switch: Description and Operation NV243 SWITCH-SELECTOR DESCRIPTION The selector switch assembly (1) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: ^ the 2WD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 5013 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 > Page 5014 Four Wheel Drive Selector Switch: Description and Operation NV244 GenII SWITCH-TRANSFER CASE SELECTOR DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: ^ either of the neighboring valid positions. ^ as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: ^ the AWD position. ^ an invalid fault position. ^ a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: ^ a valid in-between position. ^ an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: ^ the T-Case NEUTRAL position. ^ an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. ^ A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. ^ A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. ^ If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. ^ No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Gear Sensor/Switch: Locations Left Transmission (RFE) Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 5018 Left Front Transfer Case Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 5019 Gear Sensor/Switch: Diagrams Assembly - Shift Motor/Mode Sensor C1 (ETC) Assembly - Shift Motor/Mode Sensor C2 (ETC) Sensor-Transfer Case Position (MTC Except Power Wagon) Sensor-Transfer Case Position (MTC Power Wagon) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 Gear Sensor/Switch: Description and Operation NV243 Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 5022 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 5023 Gear Sensor/Switch: Description and Operation NV244 GenII Sensor-Mode SENSOR-MODE DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B. C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES vs. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV243 > Page 5024 MODE SENSOR CHANNEL STATES Assembly-Shift Motor/Mode Sensor ASSEMBLY-SHIFT MOTOR/MODE SENSOR DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads. OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 Gear Sensor/Switch: Service and Repair NV243 ASSEMBLY-SHIFT MOTOR/MODE SENSOR REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NV243 > Page 5027 Gear Sensor/Switch: Service and Repair NV244 GenII REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16 - 24 Nm (12 - 18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. On vehicles equipped with a gasoline engine, the ABS indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. On vehicles equipped with a diesel engine, the ABS indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ABS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5036 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5037 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5038 Electronic Brake Control Module: Diagrams Module-Antilock Brakes C1 Module-Antilock Brakes C2 (AWAL) Module-Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5039 Electronic Brake Control Module: Description and Operation The Antilock Brake Module (ABM) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a DRB III. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5040 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a DRB 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 N.m (16 in.lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The HCU (1) consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. The valves modulate brake pressure during antilock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. NOTE: The three modes mentioned below do occur but not necessarily in the order listed every time. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply the brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) HCU (HYDRAULIC CONTROL UNIT) REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the two electrical harness connectors. 4. Remove the five brake lines from the HCU (1). 5. Remove HCU/CAB mounting bolts (1) and remove the HCU/CAB (1). INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRBIII. 1. Install HCU/CAB (1) on the mounts (2) and Tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the five brake lines to the HCU (1) and tighten to 19 Nm (170 inch lbs.). 3. Install the two electrical harness connectors to the HCU/CAB (1) and push down on the release to secure the connectors. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 5046 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve VALVE-RWAL REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connector. 4. Remove the brake lines from the RWAL valve (1). 5. Remove RWAL valve mounting nuts (2) and remove the RWAL valve (1). INSTALLATION 1. Install RWAL valve (1) and Tighten the nuts (2) to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the RWAL valve and tighten to 19 Nm (170 inch lbs.). 3. Install the electrical harness connector to the RWAL valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5050 Wheel Speed Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5051 Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5052 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5053 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5054 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Sensor-Wheel Speed-ABS-Rear Sensor-Wheel Speed-ABS-Right Front Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5055 Wheel Speed Sensor: Description and Operation SENSOR- WHEEL SPEED-ABS-FRONT DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be ^ Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Wheel Speed Sensor: Initial Inspection and Diagnostic Overview WHEEL-TONE DIAGNOSIS AND TESTING REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRBIII scan tool is used to diagnose the Antilock Brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5058 Wheel Speed Sensor: Component Tests and General Diagnostics SENSOR-WHEEL SPEED-ABS-REAR DIAGNOSIS AND TESTING REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRBIII scan tool is used to diagnose the RWAL system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front SENSOR- WHEEL SPEED-ABS-FRONT REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5061 Wheel Speed Sensor: Service and Repair Rear SENSOR-WHEEL SPEED-ABS-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud (2) and install the nut. 7. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding Brake Bleeding: Service and Repair Hydraulic Brake Booster Bleeding HYDRAULIC BOOSTER STANDARD PROCEDURE BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 5066 Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 5067 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE MANUAL BLEEDING Use Mopar(R) brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. PRESSURE BLEEDING Use Mopar(R) brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 5068 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation Brake Pedal Assy: Description and Operation PEDAL DESCRIPTION NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot shaft pin (3) and bushings (2). If the bushings (2) become dry a spray lubricant can be used to eliminate noises. The booster push rod is attached to the pedal with a clip (1). The pedal (4), bushings (2), pivot pin (3) and support bracket are not serviceable components. OPERATION The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod is depressed which moves the booster secondary rod. The booster secondary rod depress the master cylinder piston. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 5072 Brake Pedal Assy: Service and Repair PEDAL REMOVAL NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. 1. Disconnect the negative battery cable. 2. Remove the steering column opening cover. 3. Remove the brake lamp switch and discard. 4. On vehicles equipped with adjustable pedals. Disconnect the adjuster cable (1) to the pedal (2). 5. Remove the steering column. 6. Remove the brake booster (5). 7. Disconnect the electrical connectors. 8. Remove the module mounting bolts. 9. Disconnect the accelerator pedal cable. 10. Remove the pedal assembly mounting nuts/fasteners (4). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 5073 1. Install the pedal assembly (4) to the vehicle. 2. Install the mounting bolts (3) and tighten to 28 Nm (21 ft. lbs.). 3. Reconnect the accelerator cable (1) to the pedal (2). 4. Install the module mounting bolts and tighten to 38 Nm (28 ft. lbs.). 5. Reconnect the electrical connectors. 6. Install the brake booster. 7. Install the steering column. 8. Install a new brake lamp switch. 9. On vehicles equipped with adjustable brake pedal. Reconnect the electrical connector to the motor and the adjuster cable at the pedal. 10. Install the steering column opening cover. 11. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Light Duty (LD) Calipers Brake Caliper: Description and Operation Light Duty (LD) Calipers CALIPERS-DISC BRAKE DESCRIPTION LIGHT DUTY (LD) CALIPERS The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied. friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Light Duty (LD) Calipers > Page 5079 Brake Caliper: Description and Operation Light Duty (HD) Calipers CALIPERS-DISC BRAKE DESCRIPTION HEAVY DUTY (HD) CALIPERS The calipers are a dual piston type in the front & rear. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied. friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper Brake Caliper: Service and Repair Disc Brake Caliper Front Disc Brake Caliper CALIPERS-DISC BRAKE FRONT REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Compress the disc brake caliper. 4. Remove the banjo bolt and discard the copper washer. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper (2). DISASSEMBLY DISC BRAKE CALIPER 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5082 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5083 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY DISC BRAKE CALIPER CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. NOTE: Verify seal is fully seated and not twisted. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5084 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): ^ 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar(R) brake grease or Dow Corning 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5085 FRONT NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper (2). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.). 3. Install the caliper slide pin bolts. tighten to 32 Nm (24 ft. lbs.). 4. Bleed the base brake system. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Rear Disc Brake Caliper CALIPERS-DISC BRAKE REAR REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 4. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 5. Remove the caliper slide bolts (3). 6. Remove the caliper (6) from vehicle. DISASSEMBLY DISC BRAKE CALIPER 1. Drain the brake fluid from caliper. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5086 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5087 9. Remove piston seals (3) from caliper (1). 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY DISC BRAKE CALIPER CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5088 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): ^ 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar(R) brake grease or Dow Corning 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5089 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. INSTALLATION REAR 1. Install caliper (6) to the caliper adapter (1). 2. Coat the caliper mounting slide pin bolts (3) with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose (4) to the caliper (6) with new seal washers and tighten fitting bolt to 27 Nm (245 inch lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Bleed the base brake system. 6. Install the wheel and tire assemblies. 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5090 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Front ADAPTER - DISC BRAKE CALIPER REMOVAL FRONT 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper (1). 4. Remove the bolts (2) securing the caliper adapter to the steering knuckle. 5. Remove the caliper adapter (1). INSTALLATION FRONT 1. Install the caliper adapter to the steering knuckle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5091 2. Install the caliper adapter mounting bolts (2) and tighten to 176 Nm (130 ft. lbs.) LD or tighten to 339 Nm (250 ft. lbs.) HD. 3. Install the disc brake caliper (1). 4. Install the tire and wheel assembly. 5. Remove the support and lower the vehicle. Rear ADAPTER - DISC BRAKE CALIPER REMOVAL REAR 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5092 10. Remove the caliper adapter (1). INSTALLATION REAR 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft. lbs.) LD or tighten to 197 Nm (145 ft. lbs.) HD. 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5093 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Mount MOUNT-DISC BRAKE CALIPER ADAPTER REMOVAL - REAR 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (3) attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount (1) from the axle housing (2). INSTALLATION 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate on axle flange. Tighten attaching bolts (3) to 68 Nm (50 ft. lbs.) LD or tighten to 203 Nm (150 ft. lbs.) HD. 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front PADS - BRAKE FRONT REMOVAL 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper. 4. Remove the caliper (1). 5. Remove the caliper (1) by tilting the top up and off the caliper adapter (2). NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5098 7. Remove the inboard brake shoe (1) from the caliper adapter (2). 8. Remove the outboard brake shoe (1) from the caliper adapter (2). NOTE: Anti-rattle springs are not interchangeable. 9. Remove the top anti-rattle springs (2) from the caliper adapter (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5099 10. Remove the bottom anti-rattle springs (2) from the caliper adapter (1). INSTALLATION 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper mounting adapter (1) and anti-rattle springs (2). 3. Lubricate anti-rattle springs with Mopar(R) brake grease. NOTE: Anti-rattle springs are not interchangeable. 4. Install new top anti-rattle springs (2). 5. Install new bottom anti-rattle springs (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5100 6. Install inboard brake shoe (1) in adapter (2). 7. Install outboard brake shoe (1) in adapter (2). 8. Tilt the top of the caliper (1) over rotor and under adapter (2). Then push the bottom of the caliper down onto the adapter. 9. Install caliper (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5101 10. Install wheel and tire assemblies and lower vehicle. 11. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 12. Top off master cylinder fluid level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5102 Brake Pad: Service and Repair Rear PADS - BRAKE REAR REMOVAL 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. Compress the caliper. 4. Remove caliper slide bolts (3). NOTE: Do not allow brake hose to support caliper assembly. 5. Remove the caliper (3) and then tilt the top up and off the caliper adapter. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5103 6. Remove inboard brake shoe (1) from the caliper adapter (2). 7. Remove outboard brake shoe (1) from caliper adapter (2). NOTE: Anti-rattle springs are not interchangeable. 8. Remove the top anti-rattle spring (2) from the caliper adapter (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5104 9. Remove the top anti-rattle spring (2) from the caliper adapter (1). INSTALLATION 1. Clean caliper mounting adapter (1) and anti-rattle springs (2). 2. Lubricate anti-rattle springs with Mopar(R) brake grease. NOTE: Anti-rattle springs are not interchangeable. 3. Install new top anti-rattle spring (2). 4. Install new bottom anti-rattle spring (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5105 5. Install inboard brake shoe (1) in adapter (2). 6. Install outboard brake shoe (1) in adapter (2). 7. Tilt the bottom of the caliper (3) over rotor (1) and under adapter. Then push the top of the caliper down onto the adapter. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5106 8. Install caliper (6). 9. Install wheel and tire assemblies and lower vehicle. 10. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 11. Top off master cylinder fluid level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front/Rear Disc Brake Rotor Maximum Runout LD ........................................................................................................................... ......................................... 0.050 mm (0.002 inch) Front Disc Brake Rotor Maximum Runout SRT-10 ............................................................................................................................................................. 0.050 mm (0.002 inch) Rear Disc Brake Rotor Maximum Runout SRT-10 ............................................................................................................................................................. 0.050 mm (0.002 inch) Front/Rear Disc Brake Rotor Maximum Runout HD SRW ................................................................................................................................................ 0.131 mm (0.005 inch) Rear Disc Brake Rotor Maximum Runout HD DRW ......................................................................................................................................................... 0.328 mm (0.012 inch) Front/Rear Disc Brake Rotor Maximum Thickness Variation LD ................................................................................................................................... 0.012 mm (0.0005 inch) Front Disc Brake Rotor Maximum Thickness Variation SRT-10 ...................................................................................................................................... 0.012 mm (0.0005 inch) Rear Disc Brake Rotor Maximum Thickness Variation SRT-10 ...................................................................................................................................... 0.012 mm (0.0005 inch) Front/Rear Disc Brake Rotor Maximum Thickness Variation Loose Rotor HD ........................................................................................................................ 0.013 mm (0.0005 inch) Minimum Front Rotor Thickness LD ........................................................................................................................................................ ............................................ 26.4 mm (1.039 inch) SRT-10 ................................................................ ............................................................................................................................ 33.9 mm (1.344 inch) HD ............................................................................................................................................... ......................................................... 34 mm (1.33 inch) Minimum Rear Rotor Thickness LD ........................................................................................................................................................ ............................................ 20.4 mm (0.803 inch) HD ....................................................................... .......................................................................................................................... 28.39 mm (1.117 inch) SRT-10 ....................................................................................................................................... ..................................................... 28.4 mm (1.118 inch) Rear Disc Brake Rotor Max Drum Diameter SRT-10 & HD .............................................................................................................................................. 207.2 mm (8.157 inch) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5110 Brake Rotor/Disc: Testing and Inspection ROTORS DIAGNOSIS AND TESTING DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining with a disc brake lathe if surface scoring and wear are light. Replace the rotor for the following conditions: ^ Severely Scored ^ Tapered ^ Hard Spots ^ Cracked ^ Below Minimum Thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Check rotor lateral runout with dial indicator C-3339 (1). Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 inch) inward from the rotor edge. NOTE: Be sure wheel bearing has zero end play before checking rotor runout. Maximum allowable rotor runout is 0.131 mm (0.005 inch) HD. Maximum allowable rotor runout is 0.050 mm (0.002 inch) LD. ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at 6 to 12 points around the rotor face. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5111 Position the micrometer (1) approximately 25.4 mm (1 inch) from the rotor (2) outer circumference for each measurement. Thickness should not vary by more than 0.015 mm (0.0059 inch) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Brake Rotor/Disc: Service and Repair Front Brake Rotor ROTORS REMOVAL FRONT 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. NOTE: Do not allow brake hose to support caliper adapter assembly. 3. Remove the caliper (2) from the steering knuckle (1) and remove caliper adapter assembly. Fig. 1 4. Remove the extension to the rotor nuts HD DRW ONLY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 5114 5. Remove the rotor (1) from the hub/bearing (2) wheel studs. INSTALLATION FRONT 1. On models with all-wheel Antilock System (ABS) check condition of tone wheel on hub/bearing (2). If teeth on wheel are damaged, hub/bearing assembly will have to be replaced (tone wheel is not serviced separately). 2. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft. lbs.). HD DRW ONLY. 3. Install the rotor (1) onto the hub/bearing (2) wheel studs. 4. Install the caliper adapter assembly (2) and tighten adapter bolts to: 5. Install the wheel and tire assembly and lower the vehicle. 6. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 5115 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Single Rear Wheels ROTORS REMOVAL REAR 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper (3). 4. Remove the caliper adapter (2) bolts. 5. Remove the retaining clips and rotor assembly (1). INSTALLATION REAR 1. Install the rotor (1) to the axleshaft. 2. Install the caliper adapter (2). 3. Install the caliper adapter bolts and tighten the mounting bolts to 135 Nm (100 ft. lbs.) LD or 197 Nm (145 ft. lbs.). HD. 4. Install the disc brake caliper (3). 5. Install the tire and wheel assembly. 6. Lower the vehicle. Dual Rear Wheels ROTORS REMOVAL REAR DUAL WHEELS 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 5116 3. Remove the disc brake caliper. CALIPERS-DISC BRAKE REAR REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 4. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 5. Remove the caliper slide bolts (3). 6. Remove the caliper (6) from vehicle. 7. Remove the caliper adapter bolts. 8. Remove the rear axle shaft from the housing on dual rear wheels. 9. Remove the hub and rotor assembly (C3500 only). REAR - SRT-10 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 5117 1. Compress the disc brake caliper using tool #C4212F. 2. Remove the caliper pin bolts (3). 3. Remove the banjo bolt (6) and discard the copper washer. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 4. Remove the rear disc brake caliper. INSTALLATION REAR DUAL WHEELS 1. Install the hub to the rotor. Tighten the bolts (1) to 128 Nm (95 ft. lbs.). 2. Install the hub and rotor assembly. 3. Install the rear axle shaft to the housing with dual wheels. 4. Install the caliper adapter bolts 197 Nm (145 ft. lbs.) LD. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 5118 5. Install the disc brake caliper. INSTALLATION REAR - SRT-10 NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the rear disc brake caliper. 1. Ant-rattle clips 2. Disc Brake Caliper Adapter 3. Caliper slide Pin bolts 4. Caliper Adapter Bolts 5. Brake Hose 6. Banjo Bolt 2. Install the banjo bolt (6) with new copper washers to the caliper. tighten to 27 Nm (20 ft. lbs.). 3. Install the caliper pin bolts (3). tighten to 30 Nm (22 ft. lbs.). 4. Bleed the base brake system. 5. Install the tire and wheel assembly. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement 6. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding Brake Bleeding: Service and Repair Hydraulic Brake Booster Bleeding HYDRAULIC BOOSTER STANDARD PROCEDURE BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 5124 Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 5125 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE MANUAL BLEEDING Use Mopar(R) brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. PRESSURE BLEEDING Use Mopar(R) brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 5126 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Light Duty (LD) Calipers Brake Caliper: Description and Operation Light Duty (LD) Calipers CALIPERS-DISC BRAKE DESCRIPTION LIGHT DUTY (LD) CALIPERS The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied. friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Light Duty (LD) Calipers > Page 5131 Brake Caliper: Description and Operation Light Duty (HD) Calipers CALIPERS-DISC BRAKE DESCRIPTION HEAVY DUTY (HD) CALIPERS The calipers are a dual piston type in the front & rear. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied. friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper Brake Caliper: Service and Repair Disc Brake Caliper Front Disc Brake Caliper CALIPERS-DISC BRAKE FRONT REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Compress the disc brake caliper. 4. Remove the banjo bolt and discard the copper washer. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper (2). DISASSEMBLY DISC BRAKE CALIPER 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5134 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5135 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY DISC BRAKE CALIPER CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. NOTE: Verify seal is fully seated and not twisted. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5136 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): ^ 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar(R) brake grease or Dow Corning 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5137 FRONT NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper (2). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.). 3. Install the caliper slide pin bolts. tighten to 32 Nm (24 ft. lbs.). 4. Bleed the base brake system. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Rear Disc Brake Caliper CALIPERS-DISC BRAKE REAR REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 4. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 5. Remove the caliper slide bolts (3). 6. Remove the caliper (6) from vehicle. DISASSEMBLY DISC BRAKE CALIPER 1. Drain the brake fluid from caliper. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5138 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5139 9. Remove piston seals (3) from caliper (1). 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY DISC BRAKE CALIPER CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5140 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): ^ 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar(R) brake grease or Dow Corning 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5141 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. INSTALLATION REAR 1. Install caliper (6) to the caliper adapter (1). 2. Coat the caliper mounting slide pin bolts (3) with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose (4) to the caliper (6) with new seal washers and tighten fitting bolt to 27 Nm (245 inch lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Bleed the base brake system. 6. Install the wheel and tire assemblies. 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5142 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Front ADAPTER - DISC BRAKE CALIPER REMOVAL FRONT 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper (1). 4. Remove the bolts (2) securing the caliper adapter to the steering knuckle. 5. Remove the caliper adapter (1). INSTALLATION FRONT 1. Install the caliper adapter to the steering knuckle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5143 2. Install the caliper adapter mounting bolts (2) and tighten to 176 Nm (130 ft. lbs.) LD or tighten to 339 Nm (250 ft. lbs.) HD. 3. Install the disc brake caliper (1). 4. Install the tire and wheel assembly. 5. Remove the support and lower the vehicle. Rear ADAPTER - DISC BRAKE CALIPER REMOVAL REAR 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5144 10. Remove the caliper adapter (1). INSTALLATION REAR 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft. lbs.) LD or tighten to 197 Nm (145 ft. lbs.) HD. 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 5145 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Mount MOUNT-DISC BRAKE CALIPER ADAPTER REMOVAL - REAR 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (3) attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount (1) from the axle housing (2). INSTALLATION 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate on axle flange. Tighten attaching bolts (3) to 68 Nm (50 ft. lbs.) LD or tighten to 203 Nm (150 ft. lbs.) HD. 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5150 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5151 Brake Fluid: Specifications Brake Fluid ............................................................................................................................................... Mopar DOT 3 and SAE J1703 should be used If DOT 3 brake fluid is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5152 Brake Fluid: Testing and Inspection FLUID DIAGNOSIS AND TESTING BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5153 Brake Fluid: Service and Repair STANDARD PROCEDURE BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5157 Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5158 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5159 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5160 Sensor-Brake Fluid Level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring Brake Hose/Line: Service and Repair Brake Tube Flaring LINES-BRAKE STANDARD PROCEDURE DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. ISO FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. To make a ISO flare use an ISO flaring tool kit. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. 4. Position the tube in the flaring tool flush with the top of the tool bar (6). Then tighten the tool bar on the tube. 5. Install the correct size adaptor (1) on the flaring tool yoke screw. 6. Lubricate the adaptor (2). 7. Align the adaptor and yoke screw over the tube. 8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 5165 Brake Hose/Line: Service and Repair Rear Tube / Hose Assembly REAR TUBE / HOSE ASSEMBLY 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system 2. Raise and support the vehicle. 3. Remove the brake line located at the axle. 4. Remove the mounting bolt (2) for the brake hose (3) at the axle. 5. Remove the banjo bolt (1) at the caliper. 6. Remove the hose. Installation 1. Install the hose (3). 2. Install the banjo bolt (1) at the caliper and tighten fitting bolt to 27 Nm (245 inch lbs.). 3. Install the mounting bolt (2) for the brake hose (3) at the axle. 4. Install the brake line located at the axle. 5. Lower the vehicle and remove the support. 6. Remove the prop rod from the brake pedal 7. Bleed the brake system. If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 5166 Brake Hose/Line: Service and Repair Front Brake Hose FRONT HOSE REMOVAL 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the tire and wheel assembly. 4. Remove the brake hose (2) from the brake line located at the frame. 5. Remove the brake hose banjo bolt (3) at the caliper. 6. Remove the mounting bolt securing the brake hose (2) to the frame and remove the wheel speed sensor wire (4) from the brake hose (2). 7. Remove the hose. INSTALLATION 1. Install the hose (3). 2. Install the mounting bolt (1) for the brake hose (3) at the frame. 3. Install the brake hose banjo bolt at the caliper. 4. Reinstall the wheel speed sensor wire (2) to the brake hose. 5. Remove the support and lower the vehicle. 6. Remove the prop rod from the brake pedal. 7. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 5167 Brake Hose/Line: Service and Repair Rear Brake Hose REAR BRAKE HOSE REMOVAL 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the brake line (3) from the hose (1) at the frame. 4. Remove the brake hose clip (2) at the top of the hose located at the frame. 5. Remove the vent hose (2). 6. Remove the two brake lines (3) at the bottom of the hose (1) located at the axle. 7. Remove the mounting bolt for the brake hose at the axle. 8. Remove the hose. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 5168 1. Install the hose (1). 2. Install the mounting bolt for the brake hose (1) at the axle. 3. Install the two brake lines (3) at the bottom of the hose located at the axle. 4. Install the vent hose (2). 5. Install the brake hose clip (2) at the top of the hose (1) located at the frame. 6. Install the brake line (3) to the hose at the frame. 7. Lower the vehicle and remove the support. 8. Remove the prop rod from the brake pedal. 9. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation HYDRAULIC/MECHANICAL DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING Vehicles equipped with ABS use Electronic Variable Brake Proportioning (EVBP) to balance front-to-rear braking. The EVBP is used in place of a rear proportioning valve. The EVBP system uses the ABS system to control the slip of the rear wheels in partial braking range. The braking force of the rear wheels is controlled electronically by using the inlet and outlet valves located in the Integrated Control Unit (ICU). OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING EVBP is able to decrease, hold and increase rear brake pressure without activating full ABS control. Upon entry into EVBP the inlet valve for the rear brake circuit is switched on so that the fluid supply from the master cylinder is shut off. In order to decrease the rear brake pressure, the outlet valve for the rear brake circuit is pulsed. This allows fluid to enter the Low Pressure Accumulator (LPA) in the Hydraulic Control Unit (HCU) resulting in a drop in fluid pressure to the rear brakes. In order to increase the rear brake pressure, the outlet valve is switched off and the inlet valve is pulsed. This increases the pressure to the rear brakes. The EVBP will remain functional during many ABS fault modes. If both the red BRAKE and amber ABS warning indicators are illuminated, the EVBP may not be functioning. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The HCU (1) consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. The valves modulate brake pressure during antilock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. NOTE: The three modes mentioned below do occur but not necessarily in the order listed every time. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply the brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) HCU (HYDRAULIC CONTROL UNIT) REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the two electrical harness connectors. 4. Remove the five brake lines from the HCU (1). 5. Remove HCU/CAB mounting bolts (1) and remove the HCU/CAB (1). INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRBIII. 1. Install HCU/CAB (1) on the mounts (2) and Tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the five brake lines to the HCU (1) and tighten to 19 Nm (170 inch lbs.). 3. Install the two electrical harness connectors to the HCU/CAB (1) and push down on the release to secure the connectors. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 5177 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve VALVE-RWAL REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connector. 4. Remove the brake lines from the RWAL valve (1). 5. Remove RWAL valve mounting nuts (2) and remove the RWAL valve (1). INSTALLATION 1. Install RWAL valve (1) and Tighten the nuts (2) to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the RWAL valve and tighten to 19 Nm (170 inch lbs.). 3. Install the electrical harness connector to the RWAL valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Service and Repair Hydraulic System Junction Block: Service and Repair BRAKE JUNCTION BLOCK REMOVAL 1. Remove the brake lines (1) from the junction block (2). 2. Remove the junction block (2) mounting bolt and remove the junction block from the bracket. INSTALLATION 1. Position the junction block (2) on the bracket and install the mounting bolt. Tighten the mounting bolt to 23 Nm (210 inch lbs.) 2. Install the brake lines (1) into the junction block (2) and tighten to 19 - 23 Nm (170 - 200 inch lbs.) 3. Bleed the base brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation Brake Master Cylinder: Description and Operation MASTER CYLINDER DESCRIPTION A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits and has a switch for indicating low fluid levels. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 5184 Brake Master Cylinder: Testing and Inspection DIAGNOSIS AND TESTING MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15 - 20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure STANDARD PROCEDURE MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 5187 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation MASTER CYLINDER REMOVAL ALL EXCEPT HYDROBOOST 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Disconnect the electrical connector for the low fluid level. 4. Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage. 5. Remove the brake lines (3) from the master cylinder (4). 6. Remove the mounting nuts from the master cylinder (4). 7. Remove the master cylinder (4). NOTE: Gently ease the master cylinder & reservoir assembly away from the booster, During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod from its seat inside the booster. HYDR0BOOST 1. Remove the brake lines from the master cylinder. 2. Disconnect the electrical connector for the low fluid level. 3. Remove the mounting nuts (4) from the master cylinder (3). 4. Remove the master cylinder (3). NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. INSTALLATION ALL EXCEPT HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 5188 NOTE: Make sure the output rod of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly check that there is a vacuum seal present at the shoulder of the master cylinder flange and it's neck. A square seal must be present to ensure vacuum integrity with the booster. 1. Gently install the master cylinder (9) on the booster mounting studs (4). NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. 2. Install new mounting nuts and tighten to 25 Nm (221 inch lbs.). 3. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system.. HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. 1. Install the master cylinder (3) on the booster mounting studs. 2. Install new mounting nuts (4) and tighten to 25 Nm (221 inch lbs.). 3. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 5189 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation RESERVOIR-FLUID REMOVAL 1. Install the prop rod on the brake pedal to keep pressure on the brake system. 2. Remove the reservoir cap (1) and siphon fluid into a drain container. 3. Remove the electrical connector from the fluid level switch (3) in the reservoir (2). 4. Remove the reservoir mounting bolt (5). 5. Remove the reservoir (2) from the master cylinder (4) by pulling upwards. 6. Remove old grommets from cylinder body. INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. 1. Lubricate the new grommets (6) with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets (6). 2. Start the reservoir (2) in grommets (6). Then rock the reservoir back and forth while pressing downward to seat it into the grommets. 3. Install the mounting bolt (5) for the reservoir (2) to the master cylinder (4). 4. Reconnect the electrical connector to the fluid reservoir level switch (3). 5. Remove the prop rod from the vehicle. 6. Fill and bleed base brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable Parking Brake Cable: Service and Repair Front Parking Brake Cable CABLES FRONT PARKING BRAKE CABLE REMOVAL 1. Raise and support vehicle. 2. Lockout the parking brake cable (2). 3. Loosen adjusting nut to create slack in front cable. 4. Remove the front cable from the cable connector. 5. Compress cable end fitting at underbody bracket and remove the cable from the bracket. 6. Lower vehicle. 7. Push ball end of cable out of pedal clevis with small screwdriver. 8. Compress cable end fitting at the pedal bracket (1) and remove the cable (2). 9. Remove the left cowl trim and sill plate. 10. Pull up the carpet and remove the cable from the body clip. 11. Pull up on the cable and remove the cable with the body grommet. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 5195 1. From inside the vehicle, insert the cable end fitting (2) into the hole in the pedal assembly (1). 2. Seat the cable retainer in the pedal assembly (1). 3. Engage the cable ball end in clevis on the pedal assembly. 4. Route the cable through the floorpan and install the body grommet. 5. Place the carpet down and install the left cowl trim and sill plate. 6. Raise and support the vehicle. 7. Route the cable through the underbody bracket and seat the cable end fitting in the bracket. 8. Connect the cable to the cable connector. 9. Perform the park brake adjustment procedure. 10. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 5196 Parking Brake Cable: Service and Repair Rear Parking Brake Cable Rear Park Brake Cable CABLES REAR PARK BRAKE CABLE REMOVAL 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen cable adjuster nut. 4. Remove the rear park brake cable from the intermediate park brake cable. 5. Compress tabs on cable end fitting on the rear park brake cable to the frame mount bracket. Then pull the cable through the bracket. 6. Disengage the park brake cable (2) from behind the rotor assembly.. 7. Compress cable tabs on each cable end fitting at the brake cable support plate. 8. Remove the cables from the brake cable support plates. INSTALLATION REAR PARK BRAKE CABLE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 5197 1. Push each cable end (2) through the brake cable support plate hole until the cable end fitting tabs lock into place. NOTE: Pull on the cable to ensure it is locked into place. 2. Push the cable through the frame bracket. 3. Lock the left cable end fitting tabs into the frame bracket hole. 4. Install the rear cables into the tensioner rod behind the rear of the brake assembly. 5. Install the cable to the intermediate cable connector. 6. Release and remove the lock out device. 7. Perform the park brake adjustment procedure. 8. Remove the supports and lower the vehicle. Left Rear Cable CABLES LEFT REAR CABLE REMOVAL 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the left brake cable from the equalizer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 5198 5. Remove the brake cable (4) from the frame bracket. 6. Remove the brake cable (4) from the brake lever. INSTALLATION LEFT REAR CABLE 1. Install the brake cable (4) to the brake lever. 2. Install the brake cable to the frame bracket. 3. Install the left brake cable to the equalizer. 4. Adjust the brake cable at the equalizer and adjuster nut. Right Rear Cable CABLES RIGHT REAR CABLE REMOVAL 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen the brake cable at the equalizer and adjuster nut. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 5199 4. Remove the right cable from the front cable. 5. Remove the right cable from the equalizer. 6. Remove the cable from the frame bracket. 7. Remove the cable from the axle bracket. 8. Remove the cable bracket from the shock bracket. 9. Remove the brake cable (4) from the brake lever (3). INSTALLATION RIGHT REAR CABLE 1. Install the brake cable (2) to the brake lever (3). 2. Install the cable bracket to the shock bracket. 3. Install the cable to the axle bracket. 4. Install the cable to the frame bracket. 5. Install the right cable to the equalizer. 6. Install the right cable to the front cable. 7. Adjust the brake cable at the equalizer and using the adjuster nut. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair HANDLE-RELEASE REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel. 3. Disengage the park brake release linkage rod end from the park brake mechanism. 4. Lift the park brake release handle to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle. 5. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. 6. Lift the park brake release handle to access the handle mounting bracket. 7. Using a trim stick (4) or another suitable wide flatbladed tool, gently pry each of the park brake release handle (6) mounting bracket latch tabs (5) away from the retaining notches in the instrument panel receptacle. 8. With both of the park brake release handle mounting bracket latches released, slide the handle and bracket assembly down and out of the instrument panel receptacle. INSTALLATION 1. Position the park brake release handle to the instrument panel. 2. Slide the handle and bracket assembly up into the instrument panel receptacle until both of the park brake release handle (6) mounting bracket Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 5203 latches are engaged with the notches in the instrument panel receptacle. 3. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to engage the park brake release linkage rod end with the lever on the back of the park brake release handle (6). 4. Lift the park brake release handle to access and snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle over the linkage rod. 5. Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end to the park brake mechanism 6. Snap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel over the linkage rod. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair PEDAL REMOVAL 1. Release the parking brake. 2. Raise the vehicle. 3. Loosen the cable tensioner nut at the equalizer to create slack in the front cable. 4. Lower the vehicle. 5. Remove the knee bolster. 6. Disconnect the brake lamp wire from the switch on the pedal assembly (2). 7. Roll the carpet back, loosen the front cable grommet from the floorpan and the cable retainer. 8. Disengage the release rod (1) from the arm on the pedal assembly (2). 9. Remove the bolts/nuts from the pedal assembly (2) and remove the assembly. INSTALLATION 1. Position the replacement pedal assembly (1) on the dash and cowl. 2. Install the bolts/nuts (2) and tighten to 28 Nm (21 ft. lbs.). 3. Install the park brake release rod. 4. Connect the front cable to the arm on the pedal assembly (1). 5. Install the front cable grommet into the floorpan and the cable retainer, roll the carpet back. 6. Connect the wires to the brake lamp switch. 7. Install the knee bolster. 8. Raise the vehicle. 9. Adjust the parking brake cable tensioner. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments ADJUSTMENTS PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. 3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from the axleshaft. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. 5. Using Brake Shoe Gauge, Special Tool C-3919 (1), or equivalent, accurately measure the inside diameter of the park brake drum portion (2) of the rotor. 6. Using a ruler (2) that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5210 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 (2) by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 (2) or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on the axleshaft. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter. 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.) LD, 197 Nm (145 ft. lbs.) HD SRW, 210 Nm (155 ft. lbs.) HD DRW. 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. WITH ADJUSTING TOOL Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. 1. Be sure parking brake lever is fully released. 2. Raise vehicle so rear wheels can be rotated freely. 3. Remove plug from each access hole in brake support plates. 4. Loosen parking brake cable adjustment nut until there is slack in front cable. 5. Insert adjusting tool (4) through support plate access hole (1) and engage tool in teeth of adjusting screw star wheel (2). 6. Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. 7. Push and hold adjuster lever away from star wheel with thin screwdriver (3). 8. Back off adjuster screw star wheel until brake drag is eliminated. 9. Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. 10. Install support plate access hole plugs. 11. Adjust parking brake cable and lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5211 12. Depress park brake pedal and make sure park brakes hold the vehicle stationary. 13. Release park brake pedal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5212 Parking Brake Shoe: Service and Repair SHOES REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the disc brake rotor. 5. Lockout the parking brake cable (2). 6. Disengage the park brake cable (2) from behind the rotor assembly to allow easier disassembly of the park brake shoes. 7. Remove the axleshaft (1). 8. Disassemble the rear park brake shoes (4). CLEANING - REAR DRUM IN HAT BRAKE Clean the individual brake components, including the support plate exterior, with a water dampened cloth or with brake cleaner. Do not use any other Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5213 cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. INSPECTION - REAR DRUM IN HAT BRAKE As a general rule, riveted brake shoes (2) should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes (2) exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly (5). Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs (3) and retainer components (4) if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate (1), replace the support plate if any of the pads are worn or rusted through. Also replace the plate (1) if it is bent or distorted. INSTALLATION NOTE: On a new vehicle or after parking brake lining replacement, it is recommended that the parking brake system be conditioned prior to use. This is done by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal. 1. Reassemble the rear park brake shoes (1) or. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5214 2. Install the axleshaft (1). 3. Install the park brake cable to the lever behind the support plate. 4. Unlock the park brake cable. 5. Install the disc brake rotor. 6. Install the disc brake caliper. 7. Adjust the rear brake shoes. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments TENSIONER-CABLE ADJUSTMENTS CABLE TENSIONER NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise the vehicle. 2. Back off the cable tensioner adjusting nut (5) to create slack in the cables. 3. Remove the rear wheel/tire assemblies. Then remove the brake rotors. 4. Verify the brakes are in good condition and operating properly. 5. Verify the park brake cables operate freely and are not binding, or seized. 6. Check the rear brake shoe adjustment with standard brake gauge. 7. Install the rotors and verify that the rotors rotate freely without drag. 8. Install the wheel/tire assemblies. 9. Lower the vehicle enough for access to the park brake foot pedal. Then fully apply the park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise the vehicle again. 11. Mark the tensioner rod 6.35 mm (1/4 inch) from edge of the tensioner (2). 12. Tighten the adjusting nut (5) on the tensioner rod until the mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower the vehicle until the rear wheels are 15 - 20 cm (6 - 8 inch) off the shop floor. 14. Release the park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation A brake indicator is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of a stencil-like cutout of the word "BRAKE" and the International Control and Display Symbol icon for "Brake Failure" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the brake indicator is illuminated by the instrument cluster for about two seconds as a bulb test. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. The CAB can also send brake lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the On position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to testing. The park brake switch input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 5221 Parking Brake Warning Lamp: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired park brake switch input to the EMIC may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Antilock Brake (CAB), the Programmable Communications Interface (PCI) data bus, or the electronic message inputs also used by the EMIC to provide brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAB, the PCI data bus, and the electronic message inputs for the brake indicator operation requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5225 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5226 Switch-Parking Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5227 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5228 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5229 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5230 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection Hydraulic Brake Booster: Testing and Inspection BOOSTER-HYDRO-BOOST BRAKE DIAGNOSIS AND TESTING HYDRAULIC BOOSTER The hydraulic booster uses hydraulic pressure from the power steering pump. Before diagnosing a booster problem, first verify the power steering pump is operating properly. Perform the following checks. ^ Check the power steering fluid level. ^ Check the brake fluid level. ^ Check all power steering hoses and lines for leaks and restrictions. ^ Check power steering pump pressure. NOISES The hydraulic booster unit will produce certain characteristic booster noises. The noises may occur when the brake pedal is used in a manner not associated with normal braking or driving habits. HISSING A hissing noise may be noticed when above normal brake pedal pressure is applied, 40 lbs. or above. The noise will be more noticeable if the vehicle is not moving. The noise will increase with the brake pedal pressure and an increase of system operating temperature. CLUNK-CHATTER-CLICKING A clunk-chatter-clicking may be noticed when the brake pedal is released quickly, after above normal brake pedal pressure is applied 50 - 100 lbs.. BOOSTER FUNCTION TEST With the engine off depress the brake pedal several times to discharge the accumulator. Then depress the brake pedal using 40 lbs. of force and start the engine. The brake pedal should fall and then push back against your foot. This indicates the booster is operating properly. ACCUMULATOR LEAKDOWN 1. Start the engine, apply the brakes and turn the steering wheel from lock to lock. This will ensure the accumulator is charged. Turn off the engine and let the vehicle sit for one hour. After one hour there should be at least two power assisted brake application with the engine off. If the system does not retain a charge the booster must be replaced. 2. With the engine off depress the brake pedal several times to discharge the accumulator. Grasp the accumulator and see if it wobbles or turns. If it does the accumulator has lost a gas charge and the booster must be replaced. SEAL LEAKAGE If the booster leaks from any of the seals the booster assembly must be replaced. ^ INPUT ROD SEAL (3): Fluid leakage from rear end of the booster. ^ PISTON SEAL (6): Fluid leakage from vent at front of booster. ^ HOUSING SEAL (4): Fluid leakage between housing and housing cover. ^ SPOOL VALVE SEAL (7): Fluid leakage near spool plug. ^ RETURN PORT FITTING SEAL (8): Fluid leakage from port fitting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 5235 HYDRAULIC BOOSTER DIAGNOSIS CHART Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Master Cylinder Hydraulic Brake Booster: Service and Repair Master Cylinder MASTER CYLINDER REMOVAL ALL EXCEPT HYDROBOOST 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Disconnect the electrical connector for the low fluid level. 4. Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage. 5. Remove the brake lines (3) from the master cylinder (4). 6. Remove the mounting nuts from the master cylinder (4). 7. Remove the master cylinder (4). NOTE: Gently ease the master cylinder & reservoir assembly away from the booster, During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod from its seat inside the booster. HYDR0BOOST 1. Remove the brake lines from the master cylinder. 2. Disconnect the electrical connector for the low fluid level. 3. Remove the mounting nuts (4) from the master cylinder (3). 4. Remove the master cylinder (3). NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. INSTALLATION ALL EXCEPT HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Master Cylinder > Page 5238 NOTE: Make sure the output rod of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly check that there is a vacuum seal present at the shoulder of the master cylinder flange and it's neck. A square seal must be present to ensure vacuum integrity with the booster. 1. Gently install the master cylinder (9) on the booster mounting studs (4). NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. 2. Install new mounting nuts and tighten to 25 Nm (221 inch lbs.). 3. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system.. HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. 1. Install the master cylinder (3) on the booster mounting studs. 2. Install new mounting nuts (4) and tighten to 25 Nm (221 inch lbs.). 3. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Master Cylinder > Page 5239 Hydraulic Brake Booster: Service and Repair Removal REMOVAL NOTE: If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the booster. 1. With engine off depress the brake pedal 5 times to discharge the accumulator. 2. Remove brake lines from master cylinder. 3. Remove mounting nuts from the master cylinder. 4. Remove the bracket from the hydraulic booster lines and master cylinder mounting studs. 5. Remove the master cylinder (3). 6. Remove the return hose (4) and the two pressure lines (1&5) from the hydraulic booster (2). 7. Remove the booster push rod clip, washer and rod remove from the brake pedal. 8. Remove the mounting nuts from the hydraulic booster and remove the booster. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Master Cylinder > Page 5240 Hydraulic Brake Booster: Service and Repair Installation INSTALLATION 1. Install the hydraulic booster (2) and tighten the mounting nuts to 28 Nm (21 ft. lbs.). 2. Install the booster push rod, washer and clip onto the brake pedal. 3. Install the master cylinder (3) on the mounting studs. and tighten the mounting nuts to 23 Nm (17 ft. lbs.). 4. Install the brake lines to the master cylinder and tighten to 19 Nm (170 inch lbs.). 5. Install the hydraulic booster line bracket onto the master cylinder mounting studs. 6. Install the master cylinder mounting nuts and tighten to 23 Nm (17 ft. lbs.). 7. Install the hydraulic booster pressure lines (1&5) to the bracket and booster. 8. Tighten the pressure lines to 41 Nm (30 ft. lbs.). NOTE: Inspect O-rings on the pressure line fittings to insure they are in good condition before installation. Replace O-rings if necessary. 9. Install the return hose (4) to the booster. 10. Bleed base brake system. 11. Fill the power steering pump with fluid. CAUTION: MOPAR (MS-9602) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. 12. Bleed the hydraulic booster. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Master Cylinder > Page 5241 Hydraulic Brake Booster: Service and Repair Bleeding HYDRAULIC BOOSTER STANDARD PROCEDURE BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation BOOSTER-POWER BRAKE DESCRIPTION All models use a tandem diaphragm, power brake booster (3). NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. OPERATION The booster unit consists of a single housing divided into two by a tandem diaphragm (3). The outer edge of the diaphragm is secured to the housing. A spacer block (2) is located in between the cowl and the booster housing. The booster push rod (1), connects the booster to the brake pedal and master cylinder (4), is attached to the center of the diaphragm. A check valve (5) is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5245 Vacuum Brake Booster: Testing and Inspection DIAGNOSIS AND TESTING MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15 - 20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5246 Vacuum Brake Booster: Service and Repair BOOSTER-POWER BRAKE REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum line at booster. 3. Remove clip securing booster push rod to brake pedal. 4. Remove the nuts (1) from the booster mounting studs. 5. Remove the booster (2) and gasket from front cowl panel. INSTALLATION 1. Guide the booster (2) studs into the cowl panel holes and seat the booster on the panel. 2. Install and tighten new booster attaching nuts (1) to 28 Nm (250 inch lbs.). 3. Install the booster push rod on brake pedal and install clip. 4. Install the booster check valve if removed and connect the vacuum hose to the check valve. 5. Install the master cylinder. 6. Fill and bleed the brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5251 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5252 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5253 Electronic Brake Control Module: Diagrams Module-Antilock Brakes C1 Module-Antilock Brakes C2 (AWAL) Module-Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5254 Electronic Brake Control Module: Description and Operation The Antilock Brake Module (ABM) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a DRB III. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5255 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a DRB 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 N.m (16 in.lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5260 Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5261 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5262 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5263 Sensor-Brake Fluid Level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5267 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5268 Switch-Parking Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5269 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5270 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5271 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5272 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5276 Wheel Speed Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5277 Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5278 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5279 Rear Chassis Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5280 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Sensor-Wheel Speed-ABS-Rear Sensor-Wheel Speed-ABS-Right Front Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5281 Wheel Speed Sensor: Description and Operation SENSOR- WHEEL SPEED-ABS-FRONT DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be ^ Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Wheel Speed Sensor: Initial Inspection and Diagnostic Overview WHEEL-TONE DIAGNOSIS AND TESTING REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRBIII scan tool is used to diagnose the Antilock Brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5284 Wheel Speed Sensor: Component Tests and General Diagnostics SENSOR-WHEEL SPEED-ABS-REAR DIAGNOSIS AND TESTING REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRBIII scan tool is used to diagnose the RWAL system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front SENSOR- WHEEL SPEED-ABS-FRONT REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5287 Wheel Speed Sensor: Service and Repair Rear SENSOR-WHEEL SPEED-ABS-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud (2) and install the nut. 7. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5293 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5294 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5295 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5296 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5297 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5301 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5302 Switch-Clutch Interlock (M/T) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5303 Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 5308 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5313 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5314 Relay - Starter Motor (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5315 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5316 Starter Relay: Testing and Inspection The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12 V battery to terminals 85 an 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch, Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5317 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover (2) from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation Battery Cable: Description and Operation The battery cables (1) and (3) are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires (1) have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires (3) have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or inoperative they must be replaced. Both the battery positive and negative cables are available for service replacement. Refer to the appropriate wiring information for the location of the proper battery cable wire harness diagrams. The wiring information also includes proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires provide secure and reliable connection of the battery cables to the vehicle electrical system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5322 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST WARNING: MODELS EQUIPPED WITH A DIESEL ENGINE HAVE AN AUTOMATIC SHUTDOWN (ASD) RELAY LOCATED IN THE POWER DISTRIBUTION CENTER (PDC). REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING. BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT THE ENGINE FROM STARTING. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and tested. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent a gasoline engine from starting, remove the Automatic Shutdown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM cover for ASD relay identification and location. 1. Connect the positive lead of the voltmeter (1) to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. NOTE: If the vehicle is equipped with two 12 v batteries, step #1 must be performed twice, once for each battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5323 2. Connect the positive lead of the voltmeter (1) to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. NOTE: If the vehicle is equipped with two 12 v batteries, step #2 must be performed twice, once for each battery. 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid (3) B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. NOTE: If the vehicle is equipped with two 12 v batteries, step #3 must be performed twice, once for each battery. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5324 NOTE: If the vehicle is equipped with two 12 v batteries, step #4 must be performed twice, once for each battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative Battery Cable: Service and Repair Negative REMOVAL 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamp (3). 3. Remove the bolt (4) securing the negative cable to the left front fender. 4. One at a time, trace the battery cable retaining pushpins (3), fasteners and routing clips until the cable is free from the vehicle. 5. Remove the bolt (4) securing the negative cable to the engine. 6. Remove the bolt (6) securing the negative cable to the left frame rail. 7. Remove the battery negative cable from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5327 1. Position the battery negative cable (5) in the vehicle. 2. One at a time, install the battery cable retaining pushpins (3), fasteners and routing clips until the cable is secure in the vehicle. 3. Install the bolt (6) securing the negative cable (1) to the left frame rail. 4. Install the bolt (4) securing the negative cable (5) to the engine. 5. Install the bolt (4) securing the negative cable (3) to the left front fender. 6. Connect the battery negative cable terminal clamp (3). 7. Check the vehicle for normal operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5328 Battery Cable: Service and Repair Positive REMOVAL 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamp (3). 3. Disconnect the battery positive cable terminal clamp (1). 4. Remove the nut (9) securing the cable to the Integrated Power Module (IPM) (5). 5. Disconnect the wire harness connector (6) at the IPM. 6. Disconnect the wire harness connector (7) pushpin from the IPM housing. 7. Disconnect the battery cable retaining pushpin (8) securing the cable to the battery tray. 8. Raise the vehicle on a hoist. 9. Disconnect the battery cable retaining pushpins (1) securing the cable to the left frame rail. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5329 10. Remove the nut (5) securing the cable to the starter solenoid (6). 11. Lower the vehicle. 12. Lift the terminal cap (4) and remove the nut (3) securing the cable (1) to the alternator (2). 13. Disconnect any remaining pushpins securing the cable to the vehicle. 14. Remove the battery positive cable from the vehicle. INSTALLATION 1. Position the battery positive cable (1) in the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5330 2. Install the nut (3) securing the cable (1) to the alternator (2). 3. Secure the terminal cap (4) to the alternator stud. 4. Install the cable (1) pushpin into the bracket to the left of the alternator. 5. Raise the vehicle on a hoist. 6. Install the nut (5) securing the cable to the starter solenoid (6). 7. Connect the battery cable retaining pushpins (1) securing the cable to the left frame rail. 8. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5331 9. Install the battery cable retaining pushpin (8) securing the cable to the battery tray 10. Install the wire harness connector (7) pushpin into the Integrated Power Module (IPM) (5) housing. 11. Connect the wire harness connector (6) at the IPM. 12. Install the nut (9) securing the cable to the IPM. 13. Connect the battery positive cable terminal clamp (1). 14. Connect the battery negative cable terminal clamp (3). 15. Check the vehicle for normal operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5335 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5336 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5337 Sensor-Battery Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5338 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5339 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL CAUTION: Never operate a vehicle without a battery hold down device properly installed. Damage to the vehicle, components and battery could result. 1. Verify that the ignition switch and all accessories are OFF. 2. Disconnect and isolate the battery negative cable. 3. Remove the bolt (6) from the battery hold down bracket (5) and remove the bracket from the vehicle. INSTALLATION 1. Clean and inspect the battery hold down bracket (5) and bolt (6). 2. Position the battery hold down bracket in the battery tray. CAUTION: Be certain that the hold down bracket is properly positioned in the battery tray before tightening the hold down bolt or damage to the battery and tray may result. 3. Install and tighten the battery hold down retaining bolt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5344 Battery Tray: Service and Repair Battery Tray Left Side REMOVAL 1. Remove the battery (3) from the battery tray. 2. Remove the Integrated Power Module (IPM) (5). 3. Disconnect the wire harness retainers from the battery tray assembly. 4. Disconnect the purge solenoid (6) from its mounting bracket. 5. Remove the anti-lock brake controller (if equipped) retaining bolts and support the brake controller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit. 6. Remove the left front wheelhouse splash shield. 7. Mark the location of the cruise servo (3) (if equipped) and remove the retaining screws. Position the servo out of the way. 8. Remove the battery temperature sensor from the battery tray. 9. Disconnect the left front fender ground wire. 10. Remove the remaining battery tray retaining bolts (2). 11. Remove the battery tray from the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5345 INSTALLATION 1. Position the battery tray assembly (1) and install the retaining bolts (2). 2. Connect the left front fender ground wire. 3. Install the battery temperature sensor in the battery tray. 4. Install the cruise servo (3) (if equipped) and retaining screws. 5. Install the left front wheelhouse splash shield. 6. Install the anti-lock brake controller (if equipped). 7. Install the purge solenoid (6) on its mounting bracket. 8. Connect the wire harness retainers on the battery tray assembly 9. Install the Integrated Power Module (IPM) (5). 10. Install the battery (3). Right Side REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5346 1. Remove the battery from the battery tray. 2. Remove the right front wheelhouse splash shield. 3. Disconnect the right front fender ground wire. 4. Remove fasteners from grid heater relay bracket. 5. Remove air box. 6. Remove the remaining battery tray retaining bolts. 7. Remove the battery tray from the vehicle. INSTALLATION 1. Position the battery tray assembly and install the retaining bolts. 2. Connect the right front fender ground wire. 3. Install the air box. 4. Install the grid heater relay bracket. 5. Install the right front wheelhouse splash shield. 6. Install the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views Alternator: Connector Views Generator (Except SRT) Generator (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5352 Alternator: Description and Operation The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Generator Ratings in the Specifications at the back for amperage ratings and part numbers. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5353 Alternator: Service and Repair REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove generator drive belt. Refer to Cooling System for procedure. 3. Unsnap plastic insulator cap from B+ output terminal. 4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator. 5. Disconnect field wire connector at rear of generator by pushing on connector tab. 6. Remove generator support bracket nuts (3) and bolt (4) and remove support bracket. 7. Remove 2 generator mounting bolts (1) and (3). 8. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and install 2 mounting bolts. 2. Tighten bolts. Refer to Torque Specifications. 3. Position support bracket to front of generator and install bolt and nuts. Tighten bolt/nuts. Refer to Torque Specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5354 4. Snap field wire connector into rear of generator. 5. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifications. CAUTION: - Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Cooling System. 6. Install generator drive belt. 7. Install negative battery cable to battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the PCM (Powertrain Control Module) (within the ECM for diesel engines). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of direct current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature. It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Clutch Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5362 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5363 Switch-Clutch Interlock (M/T) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5364 Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 5369 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams Starter Motor: Diagrams Starter (3.7L/4.7L/5.7L Off Road) Starter (5.7L Except Off Road) Starter-Eyelet (3.7L/4.7L/5.7L Off Road/SRT) Starter-Eyelet (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5373 Starter Motor: Testing and Inspection Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5374 Starter Motor: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. 3. NOTE: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt. 4. Remove 2 mounting bolts. 5. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire harness. 6. Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness. 7. Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud. 8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle. 9. Remove starter motor. INSTALLATION 1. Connect solenoid wire to starter motor (snaps on). 2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications. Do not allow starter motor to hang from wire harness. 3. Position starter motor to engine. 4. If equipped with automatic transmission, slide cooler tube bracket into position. 5. Install and tighten both mounting bolts. Refer to Torque Specifications. 6. Lower vehicle. 7. Connect negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5378 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5379 Relay - Starter Motor (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5380 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5381 Starter Relay: Testing and Inspection The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12 V battery to terminals 85 an 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch, Transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5382 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover (2) from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 5386 Starter Solenoid: Testing and Inspection This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. 2. Disconnect wire from solenoid field coil terminal. 3. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester (1). There should be continuity If OK, go to Step 4. If not OK, replace faulty starter motor assembly. 4. Check for continuity (2) between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Auxiliary Power Outlet: Connector Views Power Outlet (Except SRT) Power Outlet-Console (Except Base) Power Outlet-Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 8w-41-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel Auxiliary Power Outlet: Description and Operation Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5418 Auxiliary Power Outlet: Description and Operation Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5419 Auxiliary Power Outlet: Testing and Inspection POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5420 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Positive Temperature Coefficients (PTC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation Electrical Accessory Panel: Description and Operation The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5427 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5428 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5429 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5433 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5434 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5435 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5436 Fuse: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5437 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5438 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5439 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5443 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5444 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5445 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5448 Fuse Block: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5449 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5450 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5451 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5455 Battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5456 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5457 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5458 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5459 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5460 Module-Integrated Power C5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5461 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5464 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5465 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5468 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5469 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5470 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 5475 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5476 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5484 Battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5485 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5486 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5487 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5488 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5489 Module-Integrated Power C5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5490 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5493 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5494 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5497 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5498 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5499 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 5504 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5505 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5509 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5510 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5511 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5512 Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5513 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5514 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5515 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5516 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5520 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5521 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5522 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5523 Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5524 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5525 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5526 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5527 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Auxiliary Power Outlet: Connector Views Power Outlet (Except SRT) Power Outlet-Console (Except Base) Power Outlet-Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 8w-41-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel Auxiliary Power Outlet: Description and Operation Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5563 Auxiliary Power Outlet: Description and Operation Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5564 Auxiliary Power Outlet: Testing and Inspection POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5565 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Positive Temperature Coefficients (PTC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation Electrical Accessory Panel: Description and Operation The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5572 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5573 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5574 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5578 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5579 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5580 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5581 Fuse: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5582 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5583 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5584 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5588 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5589 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5590 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5593 Fuse Block: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5594 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5595 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5596 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5600 Battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5601 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5602 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5603 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5604 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5605 Module-Integrated Power C5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5606 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5609 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5610 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5613 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5614 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5615 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 5620 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5621 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5629 Battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5630 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5631 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5632 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5633 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5634 Module-Integrated Power C5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5635 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5638 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5639 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5642 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5643 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5644 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 5649 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5650 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5654 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5655 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5656 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5657 Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5658 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5659 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5660 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5661 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5665 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5666 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5667 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5668 Module - Integrated Power (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5669 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5670 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5671 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5672 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment > Page 5682 Alignment: Specifications Ride Height HEIGHT MEASUREMENT - 4WD (LD) Measure and record the height from the ground at the centerline of the rear lower control arm bolt front tip (2) Measure and record the height from the ground at the front spindle centerline (Static Load Radius) (1). Subtract the first measurement from the second measurement. The difference between the two measurement should be 58 mm (2.3 inches) ± 3 mm (0.12 inches). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5683 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION ^ CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns ^ CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire ^ TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment ^ THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5684 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height (LD only). 7. Road test the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Independent Front Suspension Alignment: Service and Repair Independent Front Suspension Height Measurement - 4WD (LD) HEIGHT MEASUREMENT - 4WD (LD) The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. 1. Inspect tires and set to correct pressure. 2. Jounce the front of the vehicle. 6. If value is greater than 61 mm (2.4 inches), tighten the torsion bar bolt until the specification is achieved. 7. If value is less than 55 mm (2.1 inches), loosen the torsion bar bolt until the specification is achieved. 8. Repeat the previous steps until the ride height is within specifications. Height Adjustment - 4WD (LD) HEIGHT ADJUSTMENT - 4WD (LD) The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure. Also when front suspension components have been replaced. This measurement must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehicle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height. NOTE: If a height adjustment has been made, perform height measurement again on both sides of the vehicle. Alignment CAMBER AND CASTER ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. Camber and caster angle adjustments involve changing the position of the upper control arm (4) in conjunction with the slotted holes in the frame brackets, Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. TOE ADJUSTMENT 4X4 SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 5687 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. CAMBER, CASTER AND TOE ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. Camber and caster angle adjustments involve changing the position of the upper control arm (4) with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. CASTER Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 5688 Moving the front or rear position of the upper control arm (4) in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. To increase positive caster angle, move the rear position (2) of the upper control arm inward (toward the engine). Move the front (1) of the upper control arm outward (away from the engine) slightly until the original camber angle is obtained using special tool 8876 to move the upper control arm for proper adjustment. CAMBER Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm (4) for proper adjustment. After adjustment is made tighten the upper control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 5689 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Independent Front Suspension > Page 5690 Alignment: Service and Repair Link/Coil ALIGNMENT LINK/COIL SUSPENSION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. CAMBER: The wheel camber angle is preset and is not adjustable. CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Caster can be adjusted by rotating the cams (3) on the lower suspension arm. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. NOTE: Toe setting will change during tightening, Make sure to verify reading after tightening. 5. Verify the right toe setting and a straight steering wheel. 6. Road test the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Page 5691 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5697 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5698 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5699 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair DRAG LINK REMOVAL 1. Remove the drag link nut (2) from the pitman arm side (1). 2. Remove the drag link nut from the knuckle side. 3. Remove the drag link (2) from the right knuckle and pitman arm (1) with Puller C-3894A (3). INSTALLATION 1. Install the drag link (2) to the pitman arm (1). Install the nut and tighten to 88 Nm (65 ft. lbs.). 2. Install the drag link to the right steering knuckle. Install the nut and tighten to 54 Nm (40 ft. lbs.) Then an additional 90°. 3. Install tie rod to the left steering knuckle and drag link. Install the nuts and tighten to 54 Nm (40 ft. lbs.) Then an additional 90°. 4. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. 5. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 Nm (45 ft. lbs.). NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers (4) and hub bearing (5). OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front-Independent Front Suspension Front Steering Knuckle: Service and Repair Front-Independent Front Suspension KNUCKLE REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the front halfshaft nut (if equipped). 5. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 8677. CAUTION: When installing Remover 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 and remove the knuckle. 7. Remove the upper ball joint nut. Separate the ball joint from the knuckle (1) with Remover 8677 (2) 8. Remove the hub/bearing from the steering knuckle. INSTALLATION CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5709 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.) (LD) or 176 Nm (130 ft. lbs.) (HD 4X2). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts (3). Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn is required) and the lower ball joint nut (3) to 52 Nm (38 ft. lbs.) (on 1500 series only an additional 90° turn is required) (LD) or 135 Nm (100 ft. lbs.) (HD 4X2). 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5710 Front Steering Knuckle: Service and Repair Front-Link/Coil KNUCKLE REMOVAL 1. Remove the hub bearing. 2. Remove tie-rod or drag link end from the steering knuckle arm. 3. Remove the ABS sensor wire and bracket from knuckle. 4. Remove the cotter pin from the upper ball stud nut. Remove the upper and lower ball stud nuts. 5. Strike the steering knuckle with a brass hammer to loosen. 6. Remove knuckle from axle tube yokes. INSTALLATION 1. Position the steering knuckle on the ball studs. 2. Install and tighten lower ball stud nut to 47 Nm (35 ft. lbs.) torque. Do not install cotter pin at this time. 3. Install and tighten upper ball stud nut to 94 Nm (70 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin. 4. Retorque lower ball stud nut to 190 - 217 Nm (140 - 160 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin. 5. Install the hub bearing. 6. Install tie-rod or drag link end onto the steering knuckle arm. 7. Install the ABS sensor wire and bracket to the knuckle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair Pitman Arm: Service and Repair PITMAN ARM REMOVAL 1. Remove the drag link from the right knuckle and pitman arm (1) with Puller C-4150A (2). 2. Mark the pitman arm (2) and shaft positions for installation reference. Remove the nut (3) and washer (4) from the pitman arm (2). 3. Remove the pitman arm (1) with Puller C-4150A (2) or equivalent pitman arm puller tool. INSTALLATION 1. Align reference marks and install pitman arm. 2. Install the lock washer and retaining nut on the pitman shaft and tighten nut to 251 Nm (185 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 5714 3. Install the drag link (1) to the pitman arm (5). Install the nut (4) and tighten to 54 Nm (40 ft. lbs.) Then an additional 90°. 4. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. 5. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 Nm (45 ft. lbs.). NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5720 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5721 Power Steering Fluid: Technical Service Bulletins Power Steering - Additive Prohibition NUMBER: 19-010-04 GROUP: Steering DATE: November 29, 2004 SUBJECT: Power Steering Fluid Contamination MODELS: 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2004 - 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5722 Power Steering Fluid: Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5723 Power Steering Fluid: Description and Operation FLUID NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5724 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4 Do not overfill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair FLUID COOLER REMOVAL 1. Drain and siphon the power steering fluid. 2. Disconnect the return and supply hoses connected to the power steering fluid cooler. 3. Remove the mounting bracket bolts (2) securing the fluid cooler (1) to the brace. (V6&V8;) (Diesel engine) 4. Remove the fluid cooler from the vehicle. INSTALLATION 1. Install the fluid cooler (1) to the vehicle. 2. Install the mounting bracket bolts (2) securing the fluid cooler (1) to the brace (V6 & V8). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 5728 (Diesel Engine). 3. Reclamp the return and supply hoses to the power steering fluid cooler (4). 4. Refill the power steering fluid. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair RESERVOIR REMOVAL 1. Drain and siphon the power steering fluid from the reservoir. 2. Remove the serpentine belt. 3. Remove the power steering pump. 4. Remove the reservoir mounting bolts. 5. Remove the reservoir. 6. Remove the rear bracket to the pump mounting bolts. INSTALLATION 1. Install the reservoir bracket to the pump housing. Do not reuse the o-rings (install new o-rings). Tighten bolts to 7 Nm (62 inch lbs.). NOTE: Ensure the reservoir is fully seated onto the pump. 2. Install the reservoir to the bracket/pump body. 3. Install the reservoir mounting bolts. Tighten bolts to 13 Nm (120 inch lbs.). 4. Install the power steering pump. 5. Install the serpentine drive belt. 6. Fill the power steering pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S Power Steering Line/Hose: Service and Repair Hoses - I.F.S Return Hose - Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 71 Nm (52 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S > Page 5736 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir to Cooler RETURN HOSE - RESERVOIR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S > Page 5737 Power Steering Line/Hose: Service and Repair Hoses - Link/Coil Return Hose - Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (2) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 Nm (38 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S > Page 5738 4. Disconnect the pressure hose (2) at the gear (4). 5. Remove the pressure hose from the vehicle. INSTALLATION NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir to Cooler RETURN HOSE - RESERVOIR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5742 Power Steering Pump: Description and Operation PUMP DESCRIPTION CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. All vehicles are equipped with a power steering fluid cooler. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. OPERATION Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump (2). The power steering pumps are constant flow rate and displacement, vane-type pumps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5743 Power Steering Pump: Testing and Inspection PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir o-rings can be replaced. Check for leaks in the following areas: ^ Pump shaft seal behind the pulley ^ Pump to reservoir o-ring ^ Reservoir cap ^ Pressure and return lines ^ Flow control valve fitting Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System Power Steering Pump: Service and Repair Standard Procedure-Flushing Power Steering System FLUSHING POWER STEERING SYSTEM Flushing is required when the power steering/hydraulic booster system fluid has become contaminated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steering gear/booster spool valve operation. 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the return line from the pump. NOTE: If vehicle is equipped with a hydraulic booster remove both return lines from the pump. 3. Plug the return line port/ports at the pump. 4. Position the return line/lines into a large container to catch the fluid. 5. While an assistant is filling the pump reservoir start the engine. 6. With the engine running at idle turn the wheel back and forth. NOTE: Do not contact or hold the wheel against the steering stops. 7. Run a quart of fluid through the system then stop the engine and install the return line/lines. 8. Fill the system with fluid and perform Steering Pump Initial Operation. 9. Start the engine and run it for fifteen minutes then stop the engine. 10. Remove the return line/lines from the pump and plug the pump port/ports. 11. Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again. 12. Install the return line/lines and perform Steering Pump Initial Operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 5746 Power Steering Pump: Service and Repair Power Steering Pump - Initial Operation POWER STEERING PUMP - INITIAL OPERATION WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. 1. Turn steering wheel all the way to the left 2. Fill reservoir up to FULL HOT level and crank engine until it just starts. (DO NOT TURN STEERING WHEEL) Then turn vehicle off. And re check fluid level, to Full COLD. 3. Crank engine again until it just starts, (DO NOT MOVE STEERING WHEEL) and turn vehicle off. Recheck fluid level to Full COLD. 4. Turn engine on again, (DO NOT MOVE STEERING WHEEL) and let the vehicle idle for 5 minutes. If possible apply a 20 in-Hg vacuum to the reservoir, while engine is idling. 5. Turn engine off and recheck fluid level, to FULL COLD. 6. If the Steering gear is replaced. ensure reservoir is at FULL HOT level, start engine and turn wheel to left. Stop Engine and recheck fluid level to FULL HOT. Start engine and turn wheel to the right. Stop engine and check fluid level is at FULL COLD. 7. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 8. Start the engine. With the engine idling maintain the fluid level. 9. Raise the front wheels off the ground. 10. Slowly turn the steering wheel lock-to-lock 20 times with the engine off while checking the fluid level. NOTE: For vehicles with long return lines or oil coolers turn wheel 40 times. 11. Lower the front wheels and let the engine idle for two minutes. 12. Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure. CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 5747 Power Steering Pump: Service and Repair Removal and Installation PUMP REMOVAL 1. Drain and siphon the power steering fluid from the reservoir. 2. Remove the serpentine belt. CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67 Nm, 40 - 50 ft. lbs.) If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled properly. If this occurs the pump needs to be replaced with a new pump. 3. Disconnect the return hose (3). 4. Disconnect the pressure hose (4). 5. Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes (1). INSTALLATION 1. Align the pump with the mounting holes in the left cylinder head. 2. Install 3 pump mounting bolts through the pulley access holes (1). Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Reconnect the pressure line (4) and return hose (3) to the pump and reservoir (2). Tighten the pressure line to 37 Nm (27 ft. lbs.). 4. Install the serpentine drive belt. 5. Fill the power steering pump. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 5748 Power Steering Pump: Service and Repair Pulley PULLEY REMOVAL CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Remove the power steering pump assembly (1). 2. Remove the pulley (2) from the pump using NOTCH 7185) power steering pulley removal tool or equivalent (3). INSTALLATION CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Replace the pulley (2) if it's bent, cracked, or loose. 2. Install the pulley (2) on the pump (1) using NOTCH 7771) power steering pulley installation tool or equivalent (3) making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install the power steering pump assembly. 4. Run engine until warm (5 minutes) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5753 Switch-Power Steering Pressure (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5754 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used with on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L engines or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5755 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 5.7L V-8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column Steering Column Bearing: Customer Interest Steering - Movement Felt in Column NUMBER: 19-003-05 GROUP: Steering DATE: May 03, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-012-04, DATED DECEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CLARIFICATION OF THE SYMPTOM AND DIAGNOSIS. SUBJECT: In And Out Movement In Steering Column OVERVIEW: This bulletin involves replacing the steering column upper bearing retainer. MODELS: 2003 - 2005 (DR) Ram Truck 2004 - 2005 (HB) Durango 2005 ((ND) Dakota NOTE: This bulletin applies to vehicles built after December 1, 2003 (MDH 1201XX) SYMPTOM/CONDITION: **The vehicle operator may describe a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver's seat** DIAGNOSIS: **While seated in the driver's seat, attempt to push and pull the steering wheel in and out. If the steering column exhibits any in and out movement, perform the Repair Procedure.** PARTS REQUIRED: REPAIR PROCEDURE: WARNING: The steering column bearing retainer is spring loaded and could fly off the shaft during this repair. Safety glasses should be worn at all times. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS. 1. Disconnect and isolate the negative battery terminal. Wait at least two minutes for the airbag system capacitor to discharge prior to disassembling the steering column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 5771 NOTE: If you are not familiar with steering column and air bag repair procedures, refer section 19 of the appropriate Service Manual for detailed procedures and safety precautions. 2. Remove the drivers air bag, steering wheel, steering column shroud, clock spring and multifunction switch. 3. Inspect the wave spring under existing retainer (Fig. 1). If spring is fully compressed, stop this procedure and replace column. If the spring is not fully compressed, proceed to step 4. 4. With the ignition key removed, rotate steering wheel until it locks (you may have to reinstall wheel in order to rotate shaft) 5. Remove bearing retainer from shaft if possible by hand, with pliers, or by placing a screwdriver underneath retainer and prying upward (Fig. 2). If the retainer can be removed, proceed to step 7. If the retainer will not come off the shaft, continue with step 6. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 5772 6. Use a sharp 1/4" chisel to score the retainer as shown (Fig. 3). Be careful not to damage any of the surrounding components with chisel. Only apply enough force to score the retainer. Do not attempt to break completely through the retainer with the chisel, this excessive force will damage the bearings. Remove any material particles that might fall into the bearing pocket. 7. Insert a screwdriver under retainer (near score mark) and pry the retainer upward until it breaks. If unsuccessful, re-score the retainer again and try again. 8. Discard old retainer and wave spring. Make sure shaft is pulled upward (toward driver) as far as possible and the bearing race and wedge are sitting tightly inside of bearing. 9. Install the new wave spring and retainer on wedge on shaft. 10. Check steering column shaft threads by hand tightening installation tool bolt provided in the kit into shaft approximately 1/2" and removing. If bolt threads easily into shaft proceed to step 9. If bolt does not thread easily into shaft, re-tap the hole using an M10 x 1.5 tap. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 5773 11. Place bearing installation tool onto shaft until it contacts retainer (Fig. 4). 12. Insert the bolt into steering column shaft. Hand tighten until threads are fully engaged. Tighten bolt down with 15 mm socket wrench until the tool bottoms out on bearing. You may hear a clicking noise as the retainer is being pressed down onto the shaft, this is normal. 13. Remove bolt and tool. Inspect retainer and spring (Fig. 1). The spring should be centered under the retainer and compressed as shown. If the spring is not centered under retainer it may be pushed towards the shaft using a screwdriver (do not damage spring). If spring needs adjusting, repeat step 12 to ensure the retainer is in the correct position. 14. Install the multifunction switch, clock spring, steering column shroud, steering wheel and drivers air bag. 15. Connect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column Steering Column Bearing: All Technical Service Bulletins Steering - Movement Felt in Column NUMBER: 19-003-05 GROUP: Steering DATE: May 03, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-012-04, DATED DECEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CLARIFICATION OF THE SYMPTOM AND DIAGNOSIS. SUBJECT: In And Out Movement In Steering Column OVERVIEW: This bulletin involves replacing the steering column upper bearing retainer. MODELS: 2003 - 2005 (DR) Ram Truck 2004 - 2005 (HB) Durango 2005 ((ND) Dakota NOTE: This bulletin applies to vehicles built after December 1, 2003 (MDH 1201XX) SYMPTOM/CONDITION: **The vehicle operator may describe a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver's seat** DIAGNOSIS: **While seated in the driver's seat, attempt to push and pull the steering wheel in and out. If the steering column exhibits any in and out movement, perform the Repair Procedure.** PARTS REQUIRED: REPAIR PROCEDURE: WARNING: The steering column bearing retainer is spring loaded and could fly off the shaft during this repair. Safety glasses should be worn at all times. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS. 1. Disconnect and isolate the negative battery terminal. Wait at least two minutes for the airbag system capacitor to discharge prior to disassembling the steering column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 5779 NOTE: If you are not familiar with steering column and air bag repair procedures, refer section 19 of the appropriate Service Manual for detailed procedures and safety precautions. 2. Remove the drivers air bag, steering wheel, steering column shroud, clock spring and multifunction switch. 3. Inspect the wave spring under existing retainer (Fig. 1). If spring is fully compressed, stop this procedure and replace column. If the spring is not fully compressed, proceed to step 4. 4. With the ignition key removed, rotate steering wheel until it locks (you may have to reinstall wheel in order to rotate shaft) 5. Remove bearing retainer from shaft if possible by hand, with pliers, or by placing a screwdriver underneath retainer and prying upward (Fig. 2). If the retainer can be removed, proceed to step 7. If the retainer will not come off the shaft, continue with step 6. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 5780 6. Use a sharp 1/4" chisel to score the retainer as shown (Fig. 3). Be careful not to damage any of the surrounding components with chisel. Only apply enough force to score the retainer. Do not attempt to break completely through the retainer with the chisel, this excessive force will damage the bearings. Remove any material particles that might fall into the bearing pocket. 7. Insert a screwdriver under retainer (near score mark) and pry the retainer upward until it breaks. If unsuccessful, re-score the retainer again and try again. 8. Discard old retainer and wave spring. Make sure shaft is pulled upward (toward driver) as far as possible and the bearing race and wedge are sitting tightly inside of bearing. 9. Install the new wave spring and retainer on wedge on shaft. 10. Check steering column shaft threads by hand tightening installation tool bolt provided in the kit into shaft approximately 1/2" and removing. If bolt threads easily into shaft proceed to step 9. If bolt does not thread easily into shaft, re-tap the hole using an M10 x 1.5 tap. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 5781 11. Place bearing installation tool onto shaft until it contacts retainer (Fig. 4). 12. Insert the bolt into steering column shaft. Hand tighten until threads are fully engaged. Tighten bolt down with 15 mm socket wrench until the tool bottoms out on bearing. You may hear a clicking noise as the retainer is being pressed down onto the shaft, this is normal. 13. Remove bolt and tool. Inspect retainer and spring (Fig. 1). The spring should be centered under the retainer and compressed as shown. If the spring is not centered under retainer it may be pushed towards the shaft using a screwdriver (do not damage spring). If spring needs adjusting, repeat step 12 to ensure the retainer is in the correct position. 14. Install the multifunction switch, clock spring, steering column shroud, steering wheel and drivers air bag. 15. Connect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover Steering Column Cover: Service and Repair Steering Column Opening Cover REMOVAL 1. Remove the two screws (1) that secure the bottom of the steering column opening cover (2) to the instrument panel. 2. Using a trim stick C-4755 or equivalent, release the two retainer clips that secure the top of the steering column opening cover to the instrument panel and remove the cover. INSTALLATION 1. Position the steering column opening cover (2) to the instrument panel and fully engage the two upper retainer clips to the instrument panel. 2. Install the two screws (1) that secure the steering column opening cover to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 5786 Steering Column Cover: Service and Repair Steering Column Opening Support Bracket REMOVAL 1. Remove the steering column opening cover from the instrument panel (1). 2. Remove the hood release handle from the steering column opening support bracket (2). 3. Disengage the retaining tabs that secure the data link connector (3) to the steering column opening support bracket and remove the data link connector from the bracket. 4. Remove the two screws (4) that secure the steering column opening support bracket (3) to the instrument panel (2). 5. Slide the steering column opening support bracket upward to disengage the two locating tabs (1) and remove the bracket. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 5787 1. Position the steering column opening bracket (3) onto the instrument panel (2) and engage to the two locating tabs (1). 2. Install the two screws (4) that secure the steering column opening bracket to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Position the data link connector (3) into the opening in the steering column opening bracket (2) and fully engage the retaining tabs that secure the connector to the bracket. 4. Install the hood release handle. 5. Install the steering column opening cover onto the instrument panel (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair Tilt Wheel Handle: Service and Repair TILT LEVER KNOB RELEASE REMOVAL 1. Remove the tilt lever handle. 2. Remove the steering column opening cover. 3. Remove the lower shroud. NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. 4. Remove the two mounting screws (3) from the tilt lever knob release bracket (1). 5. Disconnect the electrical harness plastic mounting tab (2) from the the bracket (1). 6. Unsnap the cable (2) from the bracket (1). 7. Remove the end of the cable (2) from the tilt lever knob release bracket (1). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Page 5791 1. Route the cable (2) into the tilt lever release knob bracket (1). 2. Snap the cable end (2) into the bracket (1). NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. NOTE: New screws should be used when installing the tilt lever release knob bracket to the column. 3. Install the tilt lever release knob bracket (1) to the column and install the two new mounting screws (3) Tighten the two new screws to 4.5 Nm (40 inch lbs.). 4. Install the electrical harness plastic mounting tab (2) to the bracket (1). 5. Install the lower shroud. 6. Install the steering column opening cover. 7. Install the tilt lever handle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair Steering Damper: Service and Repair DAMPER REMOVAL 1. Remove the steering damper mounting nuts and bolts. 2. Slide the damper from the isolation bushing. 3. Remove the damper. INSTALLATION 1. Install the steering damper on the axle and isolation bushing. Tighten nut to 95 Nm (75 ft. lbs.). 2. Install the steering damper on the tie rod. Tighten nut to 81 Nm (60 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal Steering Gear Seal: Service and Repair Pitman Shaft Seal PITMAN SHAFT SEAL REMOVAL 1. Separate the pitman arm from the gear box. 2. Clean exposed end of pitman shaft and housing with a wire brush. 3. Rotate the steering wheel from stop to stop and count the number of turns. 4. Center the steering wheel by rotating it from the stop back 1 1/2 turns to achieve center position. 5. Remove the pitman shaft cover bolts. NOTE: The pitman shaft will not clear the housing if it is not centered. 6. Remove the pitman shaft from the gear. 7. Remove dust seal from the housing with a special tool (2). CAUTION: Use care not to score the housing bore when prying out seals and washer. 8. Remove retaining ring with snap ring pliers. 9. Remove washer from the housing. NOTE: Tighten the slide hammer adapter 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to remove. 10. Remove oil seal from the housing with a special tool 8990 with slide hammer C-3752. (2). INSTALLATION NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring. 1. Coat the oil seal and washer with high temp grease. NOTE: Install the oil seal with the lip facing inward. Flat side of the oil seal should be against the washer. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal > Page 5800 2. Install the oil seal with special tool 8989 driver (2) and C-4171 handle (1). 3. Install backup washer. 4. Install the retainer ring with snap ring pliers. 5. Coat the dust seal with high temp grease. 6. Install the dust seal with a driver (2) and handle (1). 7. Install protective seal protector 8993 (2) over the shaft (1). 8. Install the pitman shaft into the steering gear until it fully seats into the bearing. 9. Install the new cover bolts and tighten to 68 Nm (50 ft. lbs.). 10. Install the pitman arm. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal > Page 5801 Steering Gear Seal: Service and Repair Steering Gear Input Shaft Seal STEERING GEAR INPUT SHAFT SEAL REMOVAL 1. Remove the steering gear from the vehicle. CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment 2. Mount the steering gear upside down over a drain pan in a soft jawed vise. 3. Place a drain pan under the gear and rotate the input shaft back and forth several times lock-to-lock to discharge the fluid from the steering gear 4. Drain all the remaining fluid from the gear. 5. Rotate the input shaft (4) from stop to stop and count the number of turns using a 12 point socket (2). NOTE: The pitman shaft will not clear the housing if it is not centered. 6. Center the input shaft (4) by rotating it from the stop back 1 1/2 turns to achieve center position. 7. Remove the pitman shaft. 8. Remove the four bolts securing the valve housing (1). 9. Remove the valve housing (1) from the steering gear (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal > Page 5802 10. Remove the valve housing (1) and wormshaft assembly from the steering gear housing and place the valve housing in a soft jawed vise. 11. Remove the retainer ring (3) set screw (1) from the valve housing. 12. Using special tool retainer ring wrench 8988 (1) to remove the steering gear worm thrust bearing retainer ring. 13. Separate the wormshaft assembly from the valve housing. Then remove the wormshaft assembly from the vise. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal > Page 5803 14. Remove the dust seal (3) with a pick (1). CAUTION: Use care not to score the housing bore when removing seals. 15. Remove the snap ring (2) with snap ring pliers (1). 16. Using special tool slide hammer C-3752 (1) with adapter 8990 (1) remove the oil seal. INSTALLATION 1. Inspect the piston teflon seals for damage. Replace if needed. NOTE: To replace the teflon seals, use a pick to remove the teflon o-ring and the rubber o-ring underneath. Install a new rubber o-ring in the piston seal grove and a new teflon o-ring over the top of it. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal > Page 5804 2. Install the valve into the valve housing (1). 3. Thread the retainer ring into the valve housing (1). Tighten to 97 Nm (72 ft. lbs.). NOTE: It is very important to make sure to compensate for the added length of the torque wrench when torquing to proper specifications. 4. Install the retainer ring set screw. Tighten to 2.26 Nm (20 inch lbs.). 5. Clean the steering gear housing. CAUTION: Valve assembly must be centered to the housing (1). 6. Install the valve assembly (2) into the steering gear. Tighten the new bolts to 54 Nm (40 ft. lbs.). 7. Install the input shaft seal protector 8986 (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal > Page 5805 8. Coat the new seal in high temp grease and Install the new oil seal using special tool 8987 driver (2) and C-4171 handle (3). NOTE: Drive the oil seal into the housing until the outer edge does not quite clear the snap ring groove. 9. Insert the snap ring into the housing. Using special tool 8987 driver (2) and C-4171 handle (3) push the snap ring and oil seal together until the snap ring seats in the groove. NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring. 10. Install the new dust seal using high temp grease, special tool C-4171 (driver) (3) and 8987 (handle) (2). 11. Check to make sure the gear is centered in the middle tooth (1) before installing the pitman shaft. 12. Install the pitman shaft into the steering gear. 13. Perform over-center meshload adjustment. 14. Install the steering gear to the vehicle. 15. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling Steering Shaft Coupler: Service and Repair Upper Steering Coupling UPPER STEERING COUPLING REMOVAL REMOVAL 1. Disconnect the negative battery cable. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 2. Lock the steering wheel with the tire in the straight position. 3. Remove and discard the lower pinch bolt. 4. Lower the steering coupler shaft from the column. 5. Remove the upper steering coupling shaft (2) seal by pushing in the four tags (1) securing it to the panel. 6. Remove and discard the lower coupler pinch bolt (1) from the lower steering coupling shaft (1). 7. Remove the upper steering coupling shaft (3) from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5810 1. Install the upper steering coupling shaft (3) to the vehicle. 2. Install the upper steering coupling shaft seal (2) by pushing it in securing the four tangs (1) to the panel. NOTE: Note: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used. 3. Install the steering coupler shaft (1) to the column. 4. Install the upper pinch bolt (3) use new bolt and tighten to 57 Nm (42 ft. lbs.). 5. Install the shaft to the lower coupler (1). 6. Install the lower pinch bolt (1) use new bolt and tighten to 57 Nm (42 ft. lbs.). 7. Unlock the steering wheel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5811 8. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5812 Steering Shaft Coupler: Service and Repair Lower Steering Coupling All LD & HD Except 4X4 HD LOWER STEERING COUPLING REMOVAL ALL LD & HD EXCEPT 4X4 HD 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 3. Lock the steering wheel with the tire in the straight position. 4. Remove the left front tire and wheel assembly. 5. Mark both coupler connections for proper installation. 6. Remove and discard the upper coupler pinch bolt. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5813 7. Remove and discard the lower coupler pinch bolt. INSTALLATION 1. Install the coupler to the steering rack & pinion using the marks made in the removal process. 2. Install the coupler to the intermediate shaft using the marks made in the removal process. NOTE: New pinch bolts must be used for reinstallation. 3. Install the lower pinch bolt and tighten to 57 Nm (42 ft. lbs.). 4. Install the upper pinch bolt and tighten to 57 Nm (42 ft. lbs.). 5. Install the left front tire and wheel assembly. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Unlock the steering wheel. 4X4 HD LOWER STEERING COUPLING REMOVAL 4X4 HD 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 3. Lock the steering wheel with the tire in the straight position. 4. Remove the left front tire and wheel assembly. 5. Remove and discard the upper coupler pinch bolt (1). 6. Remove and discard the lower coupler pinch bolt (2). 7. Remove the lower steering shaft coupler (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5814 1. Install the coupler (2) to the steering gear (3). 2. Install the coupler (3) to the intermediate shaft (2). NOTE: New pinch bolts must be used for reinstallation. 3. Install the lower pinch bolt (3) and tighten to 28 Nm (250 inch lbs.). 4. Install the upper pinch bolt (1) and tighten to 57 Nm (42 ft. lbs.). 5. Install the left front tire and wheel assembly. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Unlock the steering wheel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair STEERING WHEEL REMOVAL 1. Disable and remove the driver's side airbag. 2. Partially remove the steering wheel bolt (1) and leave the bolt in the column. 3. Install puller CJ98-1 (2) or equivalent using the top of the bolt to push on. 4. Remove and discard the steering wheel bolt. 5. Remove the steering wheel (1). INSTALLATION NOTE: Do not reuse the old steering wheel bolt (a new bolt must be used) 1. Install steering wheel to the column NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation. 2. Install the new steering wheel bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 3. Install the driver's side air bag. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection OUTER TIE ROD END NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator. 4. Position indicator plunger on the top side of the outer tie rod end. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the outer tie rod end. 5. Position a pry bar in order to pry downwards on the outer tie rod end. 6. If the travel exceeds 0.5 mm (0.020 inch), replace the outer tie rod end. 7. If the outer tie rod end is within specs reinstall the front tires. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Independent Front Suspension Tie Rod End: Service and Repair Independent Front Suspension OUTER TIE ROD END REMOVAL NOTE: Do not twist the boot anytime during removal or installation. 1. Loosen the jam nut. 2. Remove the outer tie rod end nut from the ball stud (1). 3. Separate the tie rod ball stud (1) from the knuckle with Remover 8677 (2). 4. Unthread the outer tie rod end (1) from the inner tie rod. INSTALLATION NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end (3) onto the inner tie rod (2), to it's original position. 2. Install the outer tie rod end (3) into the steering knuckle. 3. Tighten the ball stud nut on the ball stud to 61 Nm (45 ft. lbs.) then an additional 90°. 4. Set wheel toe pattern. 5. Tighten jam nut (1) to 75 Nm (55 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Independent Front Suspension > Page 5824 Tie Rod End: Service and Repair Link/Coil TIE ROD END REMOVAL 1. Remove tie rod nuts (1). 2. Remove tie rod from drag link and left knuckle with Puller C-4150A. INSTALLATION 1. Install tie rod (2) to the left steering knuckle and drag link. Install the nuts (1) and tighten to 54 Nm (40 ft. lbs.) Then an additional 90°. 2. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. 3. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 Nm (45 ft. lbs.). NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Wear limit Independent front suspension Upper and lower .................................................................................................................................. ....................................................... 0.5 mm (0.02 in.) Link/coil suspension Lower ................................................................................................................................................... .................................................. 2.29 mm (0.090 in.) Upper ................................................................ ....................................................................................................................................... 1.52 mm (0.060 in) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint LOWER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Mount a dial indicator solidly to the top side of the lower control arm and then zero the dial indicator. 3. Position the indicator plunger against the bottom surface of the steering knuckle. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle. 4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly. 5. If the travel exceeds 0.5 mm (0.020 inch), replace the lower ball joint. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5831 Ball Joint: Testing and Inspection Upper Ball Joint UPPER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator (1) solidly to the frame and then zero the dial indicator (1). 4. Position dial indicator plunger (1) on the top side of the upper ball joint. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the ball joint. NOTE: Use care not to pry or tear the ball joint boot (5), when checking the free play. 5. Position a pry bar (3) between the steering knuckle (4) and the upper control arm (2). Pry upwards on the upper control arm. 6. If the travel exceeds 0.5 mm (0.020 inch), replace the upper control arm since the upper ball joint is integral to the arm. 7. If the upper ball joint is within specs reinstall the front tires. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint LOWER BALL JOINT REMOVAL 1. Remove the tire and wheel assembly. 2. Remove the brake caliper and rotor. 3. Disconnect the tie rod from the steering knuckle. 4. Remove the lower ball joint nut and separate the lower ball joint from the steering knuckle (1) using special tool 8677 (2). 5. Move the halfshaft to the side and support the halfshaft out of the way (If Equipped). 6. Remove the snap ring, from the lower control arm (HD 4X2 only) NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 7. Press the ball joint (3) from the lower control arm using special tools C-4212-F (PRESS) (1), 8698-2 (RECEIVER) (4) and 8698-3 (DRIVER) (2). INSTALLATION NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5834 1. Install the ball joint (3) into the control arm (4) and press in using special tools C-4212-F (press) (1), 8698-1 (driver) (2) and 8698-3 (receiver) (5). 2. Install the ball joint boot. 3. Stake the ball joint flange in four evenly spaced places around the ball joint flange, using a chisel and hammer (LD only). 4. Replace the snap ring (HD 4X2 only) 5. Remove the support for the halfshaft and install into position (If Equipped). 6. Install the steering knuckle. 7. Install the tie rod end into the steering knuckle. 8. Install and tighten the halfshaft nut to 251 Nm (185 ft. lbs.). (If Equipped). 9. Install the brake caliper and rotor. 10. Install the tire and wheel assembly. 11. Check the vehicle ride height. 12. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5835 Ball Joint: Service and Repair Upper Ball Joint Chrysler does not provide a procedure to replace the upper ball joint separately of the upper control arm. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair BUSHINGS REMOVAL LOWER CONTROL ARM BUSHINGS - 4WD (LD) 1. Remove the lower control arm. 2. Secure the control arm in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. FRAME MOUNTED BUSHING 1. Install the bushing tool 8682-3 (receiver) (3) and 8682-4 (driver) (5) with the threaded rod (1) and the two bearings (2) as shown for the replacement of the frame bushing (7) CONTROL ARM BUSHING 1. Install bushing remover tools 8682-2 (adapter) (4), 8682-3 (receiver) (5) and 8682-4 (driver) (1) with the threaded rod (7) and the two bearings (6) as shown INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 5840 NOTE: Be careful to properly orient the bushing voids in the correct position to within ± 10°. The correct position places the long narrow void outboard (3) of the bushing and the short wide void inboard (1) of the bushing. FRAME MOUNTED BUSHING NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the new bushing into the frame using special tools 8682-3 (receiver) (3), 8682-1 (driver) (5) with the two bearings (2) and the threaded rod (1). 2. Make sure to properly orient the bushing with the voids (1&2) in the proper direction. CONTROL ARM BUSHING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 5841 1. Install the new lower control arm bushings (4) into the lower control arm using tools 8682-1 (driver) (3), 8682-5 (receiver) (6) and the two bearings (2) with the threaded rod (1). 2. Make sure to properly orient the bushing with the voids (1&2) in the proper direction. 1. Remove the control arm from the vise. 2. Install the lower control arm. 3. Reset the vehicle ride height. 4. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair TRANSMISSION CROSSMEMBER REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (3-if equipped). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5846 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles-Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles-Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5847 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft.lbs.). 2. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft.lbs.). 4. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 5. Remove the transmission support (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5848 6. Install the transfer case skid plate (3-if equipped). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers (4) and hub bearing (5). OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front-Independent Front Suspension Front Steering Knuckle: Service and Repair Front-Independent Front Suspension KNUCKLE REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the front halfshaft nut (if equipped). 5. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 8677. CAUTION: When installing Remover 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 and remove the knuckle. 7. Remove the upper ball joint nut. Separate the ball joint from the knuckle (1) with Remover 8677 (2) 8. Remove the hub/bearing from the steering knuckle. INSTALLATION CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5854 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.) (LD) or 176 Nm (130 ft. lbs.) (HD 4X2). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts (3). Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn is required) and the lower ball joint nut (3) to 52 Nm (38 ft. lbs.) (on 1500 series only an additional 90° turn is required) (LD) or 135 Nm (100 ft. lbs.) (HD 4X2). 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5855 Front Steering Knuckle: Service and Repair Front-Link/Coil KNUCKLE REMOVAL 1. Remove the hub bearing. 2. Remove tie-rod or drag link end from the steering knuckle arm. 3. Remove the ABS sensor wire and bracket from knuckle. 4. Remove the cotter pin from the upper ball stud nut. Remove the upper and lower ball stud nuts. 5. Strike the steering knuckle with a brass hammer to loosen. 6. Remove knuckle from axle tube yokes. INSTALLATION 1. Position the steering knuckle on the ball studs. 2. Install and tighten lower ball stud nut to 47 Nm (35 ft. lbs.) torque. Do not install cotter pin at this time. 3. Install and tighten upper ball stud nut to 94 Nm (70 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin. 4. Retorque lower ball stud nut to 190 - 217 Nm (140 - 160 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin. 5. Install the hub bearing. 6. Install tie-rod or drag link end onto the steering knuckle arm. 7. Install the ABS sensor wire and bracket to the knuckle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Locations > Page 5860 Switch-Disconnecting Stabilizer Bar (Smart Bar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Locations > Page 5861 Stabilizer Link: Service and Repair STABILIZER LINK - 4X4 REMOVAL 1. Raise and support the vehicle. 2. Remove the lower nut. 3. Remove the upper nut, retainers and grommets. 4. Remove the stabilizer link from the vehicle. INSTALLATION 1. Install the stabilizer link to the vehicle. 2. Install the lower nut and Tighten to 102 Nm (75 ft. lbs.). 3. Install the retainers, grommets and upper nut and Tighten to 27 Nm (20 ft. lbs.). 4. Remove the support and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation Suspension Spring ( Coil / Leaf ): Description and Operation LEAF SPRING DESCRIPTION The rear suspension system uses a multi-leaf springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing BUSHINGS REMOVAL NOTE: When removing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Remove the spring from the vehicle. 2. Make small relief cuts in the flared up end of the bushing metal being careful not to cut the spring. Use a punch to bend the flared bushing metal down for push out. 3. Position the spring eye in a press. 4. Press the bushing out with an appropriate size driver. INSTALLATION NOTE: When installing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Stake the outermetal of the bushing in a minimum of six points to retain the bushing. 3. Install the spring on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 5867 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Leaf Spring LEAF SPRING REMOVAL 1. Raise and support the vehicle. 2. Support the axle with a suitable holding fixture. 3. Remove the nuts, spring clamp bolts (5) and the plate that attach the spring (1) to the axle. 4. Remove the nuts and bolts from the spring front and rear shackle (6). 5. Remove the spring (1) from the vehicle. INSTALLATION 1. Position spring (1) on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube. 2. Align the front of the spring with the bolt hole in the front bracket. Install the eye pivot bolt and nut (4). 3. Align the rear of the spring into the shackle (6) and install the bolt and nut. 4. Tighten the spring front and rear eye pivot bolt snug do not torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 5868 5. Install the spring clamp bolts (5), plate (2) and the retaining nuts (3). 6. Remove the holding fixture for the rear axle. 7. Remove the supports and lower the vehicle so that the weight is being supported by the tires. 8. Tighten the spring clamp retaining nuts (3) to 149 Nm (110 ft. lbs.). 9. Tighten the spring front and rear pivot bolt nuts to 163 Nm (120 ft. lbs.) (LD) or 230 Nm (170 ft. lbs.) (HD) Spring Tip Inserts SPRING TIP INSERTS REMOVAL 1. Raise and support the vehicle. 2. Remove both rear tire and wheel assemblies. 3. Position a large C-Clamp (3) adjacent to the spring clinch clip (1) and clamp the leaves of the spring together CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury. 4. Use an appropriate pry bar (2) to bend open the spring clinch clip (1). If necessary, remove the existing spring clinch clip isolators. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 5869 5. Use the pry bar (2) to spread apart the leaf (1). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. 6. If necessary, remove the old spring tip liner (1). INSTALLATION 1. With the prybar still inserted between the leaves, install a new spring tip liner onto the leaf. 2. Firmly seat the spring tip liner onto the leaf. A C-Clamp (1) can be used to compress the adjacent leaves together which will seat the liner retaining pin into the hole. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 3. Apply a small amount of lubricant oil onto the tip liner wear pad. 4. Install all the spring tip liners. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 5870 5. Place one spring clinch clip isolator (1) onto the outboard side of the spring clinch clip and one isolator on the inboard side of the spring clinch clip. 6. Using large adjustable pliers (2), close the spring clinch clip (1) until the isolator contacts the leaf spring. CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 7. Use an appropriate pry bar to bend open the spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 8. Repeat procedure for the other side of the vehicle. 9. Install the tire wheel assemblies. 10. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection Suspension Strut / Shock Absorber: Testing and Inspection SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front-Independent Front Suspension SHOCK - 4X4 REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Support the lower control arm outboard end. 4. Remove the upper shock nut (2) and with the insulator and retainer (1). 5. Remove the lower shock bolt (4). 6. Remove the shock (3). INSTALLATION 1. Install the upper part of the shock (3) into the frame bracket with the insulators and retainers (1). 2. Install the nut (2) and Tighten to 54 Nm (40 ft. lbs.). 3. Install the lower part of the shock into the lower control arm and Tighten the bolt (4) to 135 Nm (100 ft. lbs.). 4. Remove the support from the lower control arm outboard end. 5. Install the tire and wheel assembly. 6. Remove the support and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5876 Suspension Strut / Shock Absorber: Service and Repair Rear SHOCK REMOVAL 1. Raise vehicle and support the axle. NOTE: The rear upper shock attachment uses a flag nut. Do not use an air tool to remove the bolt, the flag may rotate into the bottom of the bed and cause damage. Use a wrench to hold the nut when loosening. 2. Remove the upper shock bolt and nut (1). 3. Remove the lower shock bolt and nut. 4. Remove the rear shock absorber (3) from the vehicle. INSTALLATION 1. Position the shock absorber (3) in the brackets. 2. Install the bolts through the brackets and the shock. Install the flag nut (1) on the top bolt and nut on lower bolt. 3. Tighten the upper and lower bolt/nuts Tighten to 135 Nm (100 ft. lbs.). 4. Remove the support and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair Suspension Travel Bumper: Service and Repair JOUNCE BUMPER REMOVAL 1. Remove the two bolts (1) securing the jounce bumper (2) to the bracket. 2. Remove the jounce bumper (2). INSTALLATION 1. Install the jounce bumper (2). 2. Install the two bolts (1) securing the jounce bumper (2) to the bracket. Tighten the bolts to 40 Nm (30 ft. lbs.) (LD) or Tighten the bolts to 61 Nm (45 ft. lbs.) (HD). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Description and Operation Torsion Bar: Description and Operation TORSION BAR DESCRIPTION The front of the bar (3) connects to the back side of the lower suspension arm (4). The rear end of the bar is mounted in a anchor (1) that rests in the frame crossmember. OPERATION The torsion bars are used to control ride height and ride quality. The vehicle height is adjusted through an anchor adjustment bolt that increases or decreases the wind up of the torsion bar. Increasing or decreasing the bar angle changes the wind up of the suspension arms. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Crossmember Bushing Torsion Bar: Service and Repair Torsion Bar Crossmember Bushing TORSION BAR CROSSMEMBER BUSHING 1. Remove the torsion bar cross member. 2. Secure the cross member in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 3. Install special tools 8838 threaded rod, 8835-1(2), 8835-4(3) and 8835-3(4) as shown in the graphic. 4. Press out the bushing. INSTALLATION NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the new bushing into the cross member using special tools 8835-2(1), 8835-4(2) and 88353(3) with the bearing and the threaded rod 8838 (4). 2. Remove the cross member from the vise. 3. Install the torsion bar cross member. 4. Reset the vehicle ride height. 5. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Crossmember Bushing > Page 5885 Torsion Bar: Service and Repair Torsion Bar TORSION BAR REMOVAL CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. 1. Raise and support the vehicle with the front suspension hanging. 2. Remove the transfer case skid plate. NOTE: Count and record the number of turns for installation reference. 3. Mark the adjustment bolt setting. 4. Install Special Tool - 8686 (1) to the anchor arm and the cross member (2). 5. Increase the tension on the anchor arm tool until the load is removed from the adjustment bolt and the adjuster nut. 6. Turn the adjustment bolt counterclockwise to remove the bolt and the adjuster nut.. 7. Remove the Special Tool - 8686 (1), allowing the torsion bar to unload. 8. Remove torsion bar (3) and anchor (1). Remove anchor (1) from torsion bar (3). 9. Remove all foreign material from torsion bar mounting in anchor and suspension arm. 10. Inspect adjustment bolt, bearing and swivel for damage. INSTALLATION CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Crossmember Bushing > Page 5886 1. Insert torsion bar ends (3) into anchor (1) and suspension arm (4). 2. Position the anchor (1) in the frame crossmember. 3. Install Special Tool - 8686 (1) to the anchor and the crossmember (2). 4. Increase the tension on the anchor in order to load the torsion bar. 5. Install the adjustment bolt and the adjuster nut. 6. Turn adjustment bolt clockwise the recorded amount of turns. 7. Remove tool - 8686 (1) from the torsion bar crossmember (2). 8. Install the transfer case skid plate. 9. Lower vehicle and adjust the front suspension height. 10. Perform a wheel alignment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5890 Wheel Bearing: Service and Repair HUB/BEARING - 4X4 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using special tool 8677. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using special tool 8677. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. 9. Remove the support and lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 5904 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 5905 Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 5906 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5907 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5908 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, The rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5909 wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5910 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5914 Wheel Bearing: Service and Repair HUB/BEARING - 4X4 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using special tool 8677. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using special tool 8677. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. 9. Remove the support and lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair WHEEL COVER REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with Dual Rear Wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. 4. The wheel skins can now be removed from the wheel. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. INSTALLATION REAR 1. Install one 1 1/2 inch valve stem extension on each rear inner wheel. NOTE: A 3/8 inch drive 10mm deep wheel socket with a 10 inch or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 inch valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike the wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS 1500 Series Lug Nut 9/16 X 18 with 60° Cone LD .............................................................................................................................. 183 Nm (135 ft. lbs.) 2500 Series Lug Nut 9/16 X 18 with 60° Cone HD SRW .................................................................................................................... 197 Nm (145 ft. lbs.) 3500 Series Lug Nut 9/16 X 18 with Flat Washer HD DRW ............................................................................................................... 210 Nm (155 ft. lbs.) 8-lug. (SRT-10). 6-bolt pattern. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5925 Wheel Fastener: Service and Repair STUDS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using special tool C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5926 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation Accumulator HVAC: Description and Operation The A/C accumulator (5) is mounted in the engine compartment between the evaporator outlet tube (2) and the A/C suction line (6). An integral mounting bracket (4) is used to secure the accumulator to the dash panel (3). The A/C low side service port (1) is mounted to the top of the A/C accumulator. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The A/C accumulator has no serviceable parts except for the rubber O-ring seals, low side service port valve, cap and secondary retaining clips. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C accumulator is removed and installed. The A/C accumulator cannot be repaired and, if faulty or damaged, it must be replaced. Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube (2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system A filter (4) is also mounted inside the canister to trap any foreign material that may have entered the refrigerant system during assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5). On this model, the low side service port (6) is located at the top of the accumulator. The A/C accumulator cannot be repaired. If the A/C accumulator is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period or if the A/C compressor has failed, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 5931 Accumulator HVAC: Service and Repair REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover to gain access to the A/C accumulator (9). 4. Remove the secondary retaining clip (11) from the spring-lock coupler (1) that secures the A/C suction line (10) to the accumulator outlet tube (2). 5. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator. 6. Loosen the bolts (8) that secure the A/C accumulator to the bracket located on the dash panel (7). 7. Remove the secondary retaining clip (4) from the spring-lock coupler (6) that secures the accumulator inlet tube (3) to the evaporator outlet tube (5). 8. Using the proper A/C line disconnect tool, disconnect the accumulator inlet tube from the evaporator outlet tube. 9. Remove the O-ring seals from the accumulator tube fittings and discard the seals. 10. Install plugs in, or tape over the opened refrigerant system connections. 11. Remove the A/C accumulator from the engine compartment. INSTALLATION NOTE: If the A/C accumulator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. Position the A/C accumulator (9) onto the bracket located on the dash panel (7) in the engine compartment. Do not tighten the accumulator bracket Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 5932 bolts (8) at this time. 2. Remove the tape or plugs from the opened refrigerant system connections. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fittings (1 and 6). Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the spring-lock coupler that secures the accumulator inlet tube (3) to the evaporator outlet tube (5) and install the secondary retaining clip (4). 5. Tighten the accumulator bracket bolts to 4.5 N.m (40 in.lbs.). 6. Connect the A/C suction line (10) to the accumulator outlet tube (2) and install the secondary retaining clip (11). 7. Install the air filter housing cover. 8. Evacuate the refrigerant system. 9. Charge the refrigerant system. 10. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Air Door Actuator / Motor: Diagrams Actuator-Blend Door (Single Zone) Actuator Blend Door - Driver (Dual Zone) Actuator Blend Door - Passenger (Dual Zone) Actuator - Mode Door 1 (Panel To Floor) Actuator - Mode Door 2 (Defrost To Floor) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 5937 Actuator - Recirculation Door Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door Air Door Actuator / Motor: Description and Operation Actuator-Blend Door The blend door actuators are reversible, 12-volt direct current (DC), servo motors. Models with the single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models with the dual zone system have two blend-air doors, which are controlled by two blend door actuators. The blend door actuator (1) for the single zone heating-A/C system is located near the center of the HVAC housing (2), close to the dash panel. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, which is mechanically connected to only the driver side blend-air door. A second separate blend door actuator (3) located on the top of the HVAC housing is mechanically connected to the passenger side blend-air door. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connect it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The blend door actuators do not require mechanical indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control. The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 5940 polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a DRBIII(R) scan tool. The blend door actuators cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 5941 Air Door Actuator / Motor: Description and Operation Actuator-Mode Door The mode door actuators are reversible, 12-volt direct current (DC) servo motors. The heating-A/C systems on this vehicle use two mode door actuators. One for the panel/floor-air door and one for the defrost-air door. Both the panel/floor door actuator (1) and the defrost door actuator (2) are located on the driver side end of the HVAC housing (3), close to the dash panel. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The mode door actuators do not require mechanical indexing to the mode- air doors, as they are electronically calibrated by the A/C-heater control. The mode door actuators are connected to the A/C-heater control through the vehicle electrical system by dedicated two-wire leads and connectors of the HVAC wire harness. The mode door actuators can move the defrost-air door and the panel/floor-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the mode door actuators and the mode-air doors. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuators are diagnosed using using a DRBIII(R) scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 5942 The mode door actuators cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 5943 Air Door Actuator / Motor: Description and Operation Actuator-Recirculation Door The recirculation door actuator (1) is a reversible 12-volt direct current (DC) servo motor. The single recirculation door actuator is located on the passenger side end of the HVAC housing (2), on the top of the air inlet housing. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator is diagnosed using a DRBIII(R) scan tool. The recirculation door actuator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door Air Door Actuator / Motor: Service and Repair Actuator-Blend Door Single Zone/Dual Zone Driver Side NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3). 4. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the blend door actuator from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5946 1. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4). 2. Install the screws (1) that secure the blend door actuator (2) to the HVAC housing (3). Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the HVAC wire harness connector (4) to the blend door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. Dual Zone Passenger Side NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5947 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3). 4. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3). 5. Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 6. Remove the blend door actuator and bracket assembly from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5948 1. Install the blend door actuator and bracket assembly (2) onto the top of the HVAC housing (3). 2. Install the screws (1) that secure the blend door actuator and bracket assembly to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the HVAC wire harness connector (4) to the blend door actuator. NOTE: Align the guide pin on the blend door lever with the guides on the blend door linkage during installation of the blend door lever. 4. Install the blend door lever (1) onto the blend door actuator output shaft (2) and the blend door linkage (3). 5. Install the instrument panel. 6. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5949 Air Door Actuator / Motor: Service and Repair Actuator-Mode Door Panel/Floor Door Actuator NOTE: The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the screws (1) that secure the panel/floor door actuator (2) to the back of the HVAC housing (3). 4. Remove the panel/floor door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the panel/floor door actuator from the vehicle. INSTALLATION 1. Install the panel/floor door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5950 actuator output shaft (3) with those on the panel/ floor door actuator coupler (4). 2. Install the screws (1) that secure the panel/floor door actuator (2) to the HVAC housing (3). Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the HVAC wire harness connector (4) to the panel/floor door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. Defrost Door Actuator NOTE: The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the screws (1) that secure the defrost door actuator (2) to the back of the HVAC housing (3). 4. Remove the defrost door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the defrost door actuator from the vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5951 1. Install the defrost door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the defrost door actuator coupler (4). 2. Install the screws (1) that secure the defrost door actuator (2) to the HVAC housing (3). Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the HVAC wire harness connector (4) to the defrost door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5952 Air Door Actuator / Motor: Service and Repair Actuator-Recirculation Door REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the two screws (1) that secure the recirculation door actuator (2) to the side of the HVAC air inlet housing (3). 4. Remove the recirculation door actuator from the air inlet housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the recirculation door actuator from the vehicle. INSTALLATION 1. Install the recirculation door actuator (1) onto the side of the HVAC air inlet housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those in the recirculation door actuator coupler (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 5953 2. Install the two screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the HVAC wire harness connector (4) to the recirculation door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation OUTLETS-AIR There are four defroster air outlets (1) in the defroster grille (2) located on the top of the instrument panel (3). The airflow from the defroster outlets is directed by fixed vanes in the defroster grille and cannot be adjusted. The defroster air outlets are not serviceable from the defroster grille. There are two side window demister air outlets (4). One located on each end of the instrument panel top cover. The airflow from the side window demister air outlets is directed by fixed vanes in the outlets and cannot be adjusted. The side window demister air outlets are only serviced with the instrument panel top cover. There are five instrument panel air outlets (5). One air outlet is located near the driver side end of the instrument panel facing the rear of the vehicle and two outlets are located on the passenger side end of the instrument panel. Two other air outlets are located near the top of the instrument panel center bezel. Each of the instrument panel air outlets contain a grille with movable vanes (6) that are used to direct or shut off the flow of the conditioned air leaving the instrument panel outlets. The instrument panel air outlets can be serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster Air Duct: Service and Repair Duct-Defroster REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Disconnect the center radio speaker wire harness connector (1) and position it the wire harness lead out of the way. 3. Remove the screw (4) that secures the defroster duct adapter (3) to the instrument panel support. 4. Remove the defroster duct adapter from the defroster duct (5). 5. Remove the six screws (2) that secure the defroster duct to the instrument panel. 6. Remove the defroster duct from the instrument panel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5959 1. Position the defroster duct (5) into the instrument panel. 2. Install the six screws (2) that secure the defroster duct to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Install the defroster duct adapter (3) onto the defroster duct. 4. Install the screw (4) that secures the defroster duct adapter to the instrument panel support. Tighten the screw to 2.2 N.m (20 in.lbs.). 5. Connect the center radio speaker wire harness connector (1) to the speaker. 6. Install the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5960 Air Duct: Service and Repair Duct-Floor Distribution REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the HVAC housing from the vehicle. 2. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 3. Remove the floor distribution duct from the HVAC housing. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5961 1. Position the floor distribution duct (1) onto the bottom of the HVAC housing (2). 2. Install the screws (3) that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Install the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5962 Air Duct: Service and Repair Duct-Instrument Panel REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the defroster ducts. 3. Remove the two screws that secure the center distribution duct to the instrument panel support and remove the duct. 4. Remove the right side instrument panel duct adapter (2). 5. Remove the right and left side intermediate demister ducts (3 and 4). 6. Remove the left side instrument panel duct adapter (6). 7. Remove the instrument panel cover. 8. Remove the screws that secure the right and left side instrument panel ducts (1 and 5) to the instrument panel. 9. Remove the instrument panel ducts from the instrument panel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5963 1. Position the right and left side instrument panel ducts (1 and 5) onto the instrument panel. 2. Install the screws that secure the right and left side instrument panel ducts to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Install the instrument panel top cover. 4. Install the left side instrument panel duct adapter (6). 5. Install the right and left side intermediate demister ducts (3 and 4). 6. Install the right side instrument panel duct adapter (2). 7. Position the center distribution duct to the instrument panel support. 8. Install the two screws that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in.lbs.). 9. Install the defroster ducts. 10. Install the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5964 Air Duct: Service and Repair Duct-Instrument Panel Demister REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the defroster ducts. 3. Remove the two screws that secure the center distribution duct to the instrument panel support and remove the duct. 4. Remove the right side instrument panel duct adapter (2). 5. Remove the right and left side intermediate demister ducts (3 and 4). 6. Remove the left side instrument panel duct adapter (6). 7. Remove the instrument panel cover. 8. Remove the screws that secure the right and left side instrument panel ducts (1 and 5) to the instrument panel and remove the ducts. 9. Remove the screws that secure the left and right side demister ducts to the instrument panel and remove the ducts. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5965 1. Position the right and left side demister ducts into the instrument panel. 2. Install the screws that secure the right and left side demister ducts to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Position the right and left side instrument panel ducts (1 and 5) to the instrument panel. 4. Install the screws that secure the right and left side instrument panel ducts to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). 5. Install the instrument panel top cover. 6. Install the left side instrument panel duct adapter (6). 7. Install the right and left side intermediate demister ducts (3 and 4). 8. Install the right side instrument panel duct adapter (2). 9. Position the center distribution duct to the instrument panel support. 10. Install the two screws that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in.lbs.). 11. Install the defroster ducts. 12. Install the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5966 Air Duct: Service and Repair Outlets-Air REMOVAL NOTE: The instrument panel air outlets are retained to the pivots within the air outlet housings by a snap fit. 1. Using a trim stick C-4755 or equivalent (1), gently pry the panel air outlet(s) (2) out of the panel outlet housing(s) (3) as required. INSTALLATION 1. Install the air outlet (1) onto the pivot shaft (2) located at the bottom of the instrument panel air outlet housing (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Defroster > Page 5967 2. Gently push the top of the air outlet (1) onto the pivot shaft (2) at the top of the instrument panel air outlet housing (3) until it snaps into place. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5971 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5972 Sensor-Ambient Air Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5973 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5974 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5975 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views Motor-Blower Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5980 Blower Motor: Description and Operation The blower motor (1) is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (2) and squirrel cage-type blower wheel (3) that is secured to the blower motor shaft (4). The blower motor wheel is located in the HVAC air inlet housing which is mounted to the passenger side end of the HVAC housing. The blower motor can be accessed for service from underneath the instrument panel. The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. The blower motor will operate whenever the ignition switch is in the On position and the blower motor control in any position except Off. The blower motor receives a fused battery feed circuit through a fuse in the power distribution center (PDC) whenever the ignition switch is in the On position. Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor block and through the blower motor control located within the A/C-heater control. The blower motor and blower motor wheel are factory balanced and cannot be adjusted or repaired. If faulty or damaged, the blower motor and blower wheel must be replaced as an assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5981 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. For circuit descriptions and diagrams, refer to Air Conditioning/Heater in Wiring Diagrams. Possible causes of an inoperative blower motor include: - Faulty fuse - Faulty blower motor. - Faulty blower motor resistor block - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor control Possible causes of the blower motor not operating in all speeds include: - Faulty fuse - Faulty blower motor resistor block - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor control VIBRATION Possible causes of blower motor vibration include: - Improper blower motor mounting - Foreign material in blower wheel causing out of balance condition - Blower motor faulty. - Improper blower wheel mounting - Blower wheel out of balance or deformed NOISE To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: - Improper blower motor mounting - Foreign material in the HVAC air inlet housing - Blower motor faulty. - Improper blower wheel mounting Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5982 Blower Motor: Service and Repair REMOVAL NOTE: The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the HVAC wire harness lead (1) from the blower motor (2). 3. Remove the HVAC wire harness lead from the two wire harness retainers (3). 4. Remove the three screws (4) that secure the blower motor to the bottom of the HVAC housing (5). 5. Remove the blower motor from the HVAC housing. INSTALLATION 1. Position the blower motor (2) into the bottom of the HVAC housing (5). 2. Install the three screws (4) that secure the blower motor to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the HVAC wire harness lead (1) to the blower motor and install the wire harness lead into the two wire harness retainers (3). 4. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Resistor Block-Blower Motor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5989 Blower Motor Resistor: Description and Operation The blower motor resistor is mounted to the bottom of the HVAC housing, directly behind the glove box. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink (3). The blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and connector of the HVAC wire harness. The blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor switch in the heating-A/C system directs the ground path for the blower motor through the correct resistor wire to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the blower motor is applied through all of the resistor wires. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. The blower motor resistor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5990 Blower Motor Resistor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: For circuit descriptions and diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor. 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5991 Blower Motor Resistor: Service and Repair REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR RESISTOR, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTORS TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the negative battery cable. 2. Reach under the instrument panel near the blower motor (5) and disconnect the wire harness connector (2) from the blower motor resistor (4). 3. Remove the two screws (1) that secure the blower motor resistor to the HVAC housing (3). 4. Remove the blower motor resistor from the HVAC housing. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5992 1. Position the blower motor resistor (4) into the opening of the HVAC housing (3) near the blower motor (5). 2. Install the two screws (1) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Connect the wire harness connector (2) to the blower motor resistor. 4. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The blower motor is controlled by a rotary-type blower motor switch (6), mounted in the A/C-heater control (1). The switch allows the selection of one of four different blower motor speeds and includes an Off position. The blower motor switch provides a ground path through the A/C-heater control. The blower motor switch directs the ground path through the appropriate blower motor resistor wires, as required to achieve the selected blower motor speed. The blower motor switch is diagnosed using a DRBIII(R) scan tool. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C-heater control must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair BODY VENT REMOVAL 1. Remove the rear cab trim panel, Refer to Trim Panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams Clutch - A/C Compressor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 6006 Compressor Clutch: Description and Operation The A/C compressor clutch assembly consists of a stationary electromagnetic A/C clutch field coil (4), pulley bearing and pulley assembly (3), clutch plate (2) and shims (7). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch field coil and the pulley bearing and pulley assembly are both retained on the nose of the A/C compressor with snap rings (5 and 6). The clutch plate is splined to the compressor shaft and secured with a bolt (1). The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly. A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. The A/C compressor clutch components cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compressor Clutch: Initial Inspection and Diagnostic Overview NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6009 Compressor Clutch: Component Tests and General Diagnostics After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor Compressor Clutch: Service and Repair Sanden A/C Compressor REMOVAL NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness connector for the A/C compressor clutch coil from the clutch field coil wire harness connector on the top of the A/C compressor. 4. Remove the bolts that secure the A/C compressor to the mounting bracket and support the A/C compressor. 5. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) (2) into the holes of the clutch plate (1). Hold the clutch plate stationary and remove the nut. 6. Remove the clutch plate and shims. 7. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the snap ring that secures the pulley and bearing assembly (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6012 8. Install the lip of the pulley and bearing puller (Special Tool C-6141-1 or equivalent) (1) into the snap ring groove of the pulley and bearing assembly and install the shaft protector (Special Tool C-6141-2 or equivalent) (2). CAUTION: Do not apply excessive force to the end of the compressor shaft with the puller center bolt or damage to the shaft may occur. 9. Install the puller through-bolts (Special Tool C-6461 or equivalent) through the puller flange (2) and into the puller jaws (1). Turn the puller center bolt clockwise until the pulley and bearing assembly is free. 10. Remove the screw and retainer (3) from the wire harness lead (2) of the clutch field coil (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6013 11. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the snap ring that secures the clutch field coil (1) and remove the field coil. INSTALLATION CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor. 1. Install the clutch field coil (1) and using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the snap ring that secures the field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 2. Install the retainer and screw (3) over the wire harness lead (2) of the clutch field coil (1) and onto the A/C compressor. Tighten the screw to 2.2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6014 N.m (20 in.lbs.). 3. Position the pulley and bearing assembly (1) squarely onto the front of the A/C compressor. NOTE: Thread the installer fully onto the compressor shaft. Turn the installer nut until the pulley and bearing assembly is fully seated. 4. Using installer (Special Tool C-6871 or equivalent) (2), install the pulley and bearing assembly. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the snap ring that secures the pulley and bearing assembly (1) onto the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6015 6. If the original clutch plate (1) and pulley and bearing assembly are to be reused, reinstall the original shim(s) onto the compressor shaft. If a new clutch plate and/or pulley and bearing assembly are being used, install a 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the new clutch hardware package that is provided with the new clutch. 7. Install the clutch plate onto the compressor shaft. 8. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) (2) into the holes of the clutch plate (1). Hold the clutch plate stationary and install the nut that secures the clutch plate. Tighten the nut to 20 N.m (15 ft.lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. 9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications. If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained. 10. Install the bolts that secure the A/C compressor to the mounting bracket. 11. Connect the engine wire harness connector to the A/C compressor clutch coil. 12. Install the accessory drive belt. 13. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6016 Compressor Clutch: Service and Repair Denso A/C Compressor REMOVAL NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness connector for the A/C compressor clutch coil from the clutch field coil wire harness connector on the top of the A/C compressor. 4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor. 5. Remove the compressor shaft bolt (1). A band-type oil filter wrench or a strap wrench may be used to secure the clutch plate (2) during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6017 process. 6. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1). Remove the clutch plate and shim(s) (3) from the compressor shaft. 7. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor, then slide the pulley and bearing assembly off of the A/C compressor. 8. Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing (3). 9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the external snap ring (4) that secures the clutch field coil (2) to the front cover of the compressor housing, then slide the clutch field coil off of the A/C compressor. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6018 1. Align the dowel pin on the back of the clutch field coil (2) with the hole in the compressor front cover (3) and position the clutch field coil onto the A/C compressor. Be certain that the clutch coil wire harness is properly oriented and routed so that it is not pinched between the compressor front cover and the clutch field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor. 2. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), install the external snap ring (4) that secures the clutch field coil to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly 3. Install the screw that secures the clutch field coil wire harness connector bracket and ground clip to the top of the compressor housing. Tighten the screw securely. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result. 4. Install the pulley and bearing assembly (1) onto the front cover of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6019 CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 6. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) on the compressor shaft (1) against the shoulder. If a new clutch plate and/or pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 6020 7. Install the clutch plate (2) onto the compressor shaft. 8. Install the compressor shaft bolt (1). Tighten the bolt to 17.5 N.m (155 in.lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. 9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications. If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained. 10. Install the bolts that secure the A/C compressor to the engine. 11. Connect the engine wire harness connector to the A/C compressor clutch coil. 12. Install the accessory drive belt. 13. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) through the A/C clutch relay. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS 1. If no diagnostic trouble codes (DTCs) are found in the A/C-heater control and the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application), go to Step 2. If any DTCs are found, repair as required. 2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level. If the refrigerant charge level is OK, go to TESTS. If the refrigerant charge level is not OK, adjust the refrigerant charge as required. TESTS 1. Verify the battery state of charge. 2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. 3. With the A/C-heater control in the A/C mode and the blower motor at low speed, start the engine and allow it to run at a normal idle speed. 4. The A/C compressor clutch should engage immediately, and the clutch coil supply voltage should be within two volts of the battery voltage. If the coil supply voltage is OK, go to Step 5. If the coil supply voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary 5. For the acceptable A/C clutch coil current draw specifications. Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. a. If the A/C clutch coil current reading is zero, the coil is open and must be replaced. b. If the A/C clutch coil current reading is above specifications, the coil is shorted and must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Service and Repair Compressor Clutch Diode HVAC: Service and Repair NOTE: If the vehicle is equipped with dual batteries (diesel engine), be sure to disconnect the negative battery cable from both batteries. 1. Disconnect and isolate the negative battery cable(s). 2. Remove the diode from the wire harness. Note the direction of current flow (1). The band located on the end of the diode (2) indicates current flow through the diode. 3. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 4. Install the new diode in the wire harness, making sure current flow is correct. If necessary refer to the appropriate wiring diagram for current flow. Diode as shown in the wiring diagram (3). CAUTION: Do not use acid core solder when installing a new diode. Acid core solder will corrode the diode connections within the harness, which can cause A/C compressor clutch failure. 5. Solder the connections together using rosin core type solder only. 6. Tape the new diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 7. Reconnect the negative battery cable(s). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6030 Compressor Clutch Relay: Description and Operation The A/C clutch relay (1) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay The A/C clutch relay is located in the integrated power module (IPM) in the engine compartment. The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input from the powertrain control module (PCM) or engine control module (ECM) (depending on engine application), to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (86) receives a ground input from the PCM/ECM through the A/C clutch relay control circuit only when the PCM/ECM electronically pulls the circuit to ground. - The coil battery terminal (85) receives a battery current input from PTC 1 in the IPM through a fused ignition switch output (run) circuit only when the ignition switch is in the On position. - The normally open terminal (87) provides a battery current output to the A/C clutch coil through the A/C clutch relay output circuit only when the A/C clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C clutch relay coil is de-energized. The A/C clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard micro-relay and for complete HVAC wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6031 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2). NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for A/C clutch relay location. 3. Remove the A/C clutch relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for A/C clutch relay location. 1. Position the A/C clutch relay into the receptacle of the integrated power module (IPM) (2). 2. Align the A/C clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation The A/C condenser is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. The A/C condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 6035 Condenser HVAC: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the A/C discharge line and the A/C liquid line from the A/C condenser. 4. Disconnect the wire harness connector (8) from the A/C condenser cooling fan motor (7). 5. Remove the two bolts (1 and 9) that secure the A/C condenser to the front upper crossmember (2). 6. Carefully lift the A/C condenser and cooling fan assembly to disconnect the lower mounting tabs (6) from the lower mounting flanges (3) and remove the assembly from the engine compartment. 7. If required, place the A/C condenser and the cooling fan assembly on a workbench and remove the four screws (4 and 5) that secure the cooling fan to the A/C condenser and separate the fan from the condenser. INSTALLATION NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. If removed, install the condenser cooling fan onto the A/C condenser. 2. Install the four screws (4 and 5) that secure the cooling fan to the A/C condenser. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Position the A/C condenser and cooling fan assembly into the engine compartment. 4. Install the lower mounting tabs (6) into the lower mounting flanges (3). 5. Install the two bolts (1 and 9) that secure the A/C condenser to the upper front crossmember (2). Tighten the bolts to 10.5 N.m (95 in.lbs.). 6. Connect the wire harness connector (8) to the A/C condenser cooling fan motor (7). 7. Connect the A/C discharge line and the A/C liquid line onto the A/C condenser. 8. Reconnect the negative battery cable. 9. Evacuate the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 6036 10. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations Condenser Fan Motor: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 6041 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 6042 Motor-Condenser Fan (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 6049 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 6050 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views Control Assembly: Connector Views Control - A/C-Heater C1 Control - A/C-Heater C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6053 Control Assembly: Description and Operation MANUAL SINGLE ZONE The A/C-heater control (1) for the manual temperature control (MTC) single zone heating-A/C system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. NOTE: Manual A/C-heater control with optional A/C shown. Manual A/C-heater control without A/C similar. The A/C-heater control and integral computer is located in the instrument panel and contains: - a push button A/C on/off control (2). The Snow-flake button contains an LED that illuminates when the optional A/C system is in operation. - a push button rear window defogger on/off control (3). The defogger button contains an LED that illuminates when the rear window defogger system is in operation. - a rotary control knob for recirculation and mode control of the discharged air (4). - a rotary control knob for temperature control of the discharged air (5). - a rotary control knob for fan speed selection and turning the heating-A/C system off (6). The A/C-heater control cannot be repaired and, if faulty or damaged, it must be replaced. The illumination lamps for the A/C-heater control are available for service replacement. MANUAL DUAL ZONE The A/C-heater control (4) for the manual temperature control (MTC) dual zone heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. All controls are identified by ISO graphic symbols. The dual zone A/C-heater control and integral computer is located in the instrument panel and contains: - a push button A/C on/off control (1). The Snow-flake button contains an LED that illuminates when the A/C system is in operation. - a push button MAX A/C air recirculation control (2). The Recirculation button contains an LED that illuminates when the recirculation function is activated for high A/C demand. - a push button rear window defogger on/off control (3). The defogger button contains an LED that illuminates when the rear window defogger system is in operation. - two slid-type control levers for individual driver and front seat passenger temperature control of the discharged air (5 and 6). - a rotary control knob for mode control of the discharged air (7). - a rotary control knob for fan speed selection and turning the heating-A/C system off (8). The A/C-heater control cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C-Heater Control Assembly Control Assembly: Service and Repair A/C-Heater Control Assembly REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and disconnect the wire harness connectors (3 and 4) from the A/C-heater control (1). 3. Place the center bezel on a workbench and remove the screws (2) that secure the A/C-heater control to the center bezel. 4. Remove the A/C-heater control from the center bezel. INSTALLATION 1. Position the A/C-heater control (1) into the instrument panel center bezel. 2. Install the screws (2) that secure the A/C-heater control to the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Connect the wire harness connectors (3 and 4) to the back of the A/C-heater control (5) and install the instrument panel center bezel. 4. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C-Heater Control Assembly > Page 6056 Control Assembly: Service and Repair Illumination Lamp WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: There may be minor variations in the locations of the bulb/bulb holder units on the back of the A/C-heater control as a result of various optional A/C-heater control units. However, the bulb types and service procedures are identical for all of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (2) counterclockwise about 30 degrees to unlock it from the keyed opening in the A/C-heater control (1) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the bulb holder and bulb (2) with the keyed opening in the circuit board of the A/C-heater control (1). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the center bezel onto the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C-Heater Control Assembly > Page 6057 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6069 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6070 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6071 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6072 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6073 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6074 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6075 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6076 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6077 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6078 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6079 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6080 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6086 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6087 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6088 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6089 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6090 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6091 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6092 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6093 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6094 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6095 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6096 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6097 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6098 Evaporator Core: Description and Operation The A/C evaporator (1) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator and it's insulator (2) are positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator. The A/C evaporator can be serviced by removing and disassembling the HVAC housing assembly. Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. The A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6099 Evaporator Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 2. Disassemble the HVAC housing to access the A/C evaporator. 3. Remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2) and position the wire lead (3) out of the way. 4. Carefully lift the A/C evaporator out of the upper half of the HVAC housing (4). 5. Inspect all foam seals and replace as required. INSTALLATION NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. Carefully install the A/C evaporator (2) into the upper half of the HVAC housing (4). 2. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator. 3. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing. 4. Assemble the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6100 5. Install the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Sensor-Evaporator Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 6104 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the A/C evaporator. The probe (1) for evaporator temperature sensor is attached to the evaporator coil fins. The wire lead (2) for evaporator temperature sensor is routed through an opening at the back of the HVAC housing and the connector (3) is attached to the HVAC wire harness. The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a DRBIII(R) scan tool. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 6105 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Remove the wire lead for the evaporator temperature sensor (2) from the retainer located on the HVAC housing (1) and disconnect the sensor connector from the HVAC wire harness (3). 3. Remove the lower half of the HVAC housing from the upper half of the HVAC housing to gain access to the A/C evaporator. 4. Carefully remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2). 5. Remove the wire lead of the evaporator temperature sensor (3) from the upper half of the HVAC housing (4). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 6106 1. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator (2). 2. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing (4). 3. Assemble the HVAC housing. 4. Install the wire lead of the evaporator temperature sensor (2) to the retainer located on the HVAC housing (1) and connect the sensor connector to the HVAC wire harness (3). 5. Install the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation The fixed A/C orifice tube is installed in the rear section of the A/C liquid line and provides a restriction in the liquid refrigerant line between the A/C condenser and the A/C evaporator. This restriction established the pressure differential between the high and low-pressure sides of the A/C system. The A/C orifice tube includes a diffuser screen (1), O-ring seals (2) to seal it to the inner wall of the A/C liquid line, an inlet filter screen (3) and the fixed orifice (4). The fixed A/C orifice tube is used to meter the flow of liquid refrigerant into the A/C evaporator. The high-pressure liquid refrigerant from the A/C condenser expands into a low-pressure liquid as it passes through the metering orifice and diffuser screen of the A/C orifice tube. The A/C orifice tube is not serviceable. The A/C orifice tube cannot be repaired and, if faulty or plugged, it must be replaced as part of the A/C liquid line. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 6110 Expansion Block/Orifice Tube: Testing and Inspection WARNING: THE A/C LIQUID LINE BETWEEN THE A/C CONDENSER AND THE A/C ORIFICE TUBE CAN BECOME HOT ENOUGH TO BURN THE SKIN. USE EXTREME CAUTION WHEN PERFORMING THE FOLLOWING TEST TO PREVENT POSSIBLE PERSONAL INJURY. NOTE: The A/C orifice tube can be checked for proper operation using the following procedure. However, the A/C orifice tube is only serviced as a part of the A/C liquid line. If the results of this test indicate that the A/C orifice tube is obstructed or missing, the rear section of the A/C liquid line must be replaced. 1. Confirm that the refrigerant system is properly charged. 2. Start the engine. Turn on the A/C system and confirm that the compressor clutch is engaged. 3. Allow the A/C system to operate for five minutes. 4. Lightly and cautiously touch the A/C liquid line near the condenser outlet at the front of the engine compartment. The liquid line should be hot to the touch. 5. Touch the A/C liquid line near the evaporator inlet at the rear of the engine compartment. The liquid line should be cold to the touch. 6. If there is a distinct temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is in good condition. If there is little or no detectable temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is obstructed or missing and the rear section of the A/C liquid line must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 6114 Heater Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 6115 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secures the heater core bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions WARNING: - THE A/C SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - VOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE A/C REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION AND DEATH. - THE EVAPORATION RATE OF R-134A REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134A SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. CAUTION: - Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on a R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. - Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. - Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line Hose/Line HVAC: Description and Operation Coupler-Refrigerant Line Spring-lock type refrigerant line couplers (1 and 4) are used to connect the A/C suction line (6) to the A/C accumulator (5) and, the A/C accumulator and the A/C liquid line to the A/C evaporator tubes (3). Secondary retaining clips (2 and 7) are installed over the connected couplers for added protection. The spring-lock refrigerant line couplers require special disconnect tools for disengaging the two coupler halves. The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected. Two O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. A secondary retaining clip (3) is installed over the connected coupler (5) for added protection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6121 Hose/Line HVAC: Description and Operation Plumbing The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80 millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s). High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6122 Hose/Line HVAC: Description and Operation Line-A/C Discharge The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line for the 5.9L Diesel engine is serviced as an assembly with the suction line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use correct O-ring seal will cause the refrigerant system connection to leak. The A/C discharge line has no serviceable parts except the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is removed and installed. If the A/C discharge line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6123 Hose/Line HVAC: Description and Operation Line-A/C Liquid The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The liquid line for this model consist of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The liquid lines are made from light-weight aluminum, and use braze-less fittings. The front half of the liquid line includes the high-side service port and the rear half of the liquid line contains the fixed orifice tube. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is removed and installed. If the liquid line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6124 Hose/Line HVAC: Description and Operation Line-A/C Suction The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line for the 5.9L Diesel engine is serviced as an assembly with the discharge line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The A/C suction line has no serviceable parts except for the rubber O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed and installed. If the A/C suction line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 6125 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: - R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR AND R-134A CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134A SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. This is accomplished by performing a system Charge Level-Check or Fill. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the symptoms. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to Step 2. 2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the refrigerant system. 3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. 4. Proceed to Step 2 of System Low procedure. SYSTEM LOW 1. Determine if there is any R-134a refrigerant in the system. 2. Position the vehicle in a wind free work area. This will aid in detecting small leaks. 3. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the A/C system set to the following: Transmission in Park or Neutral with parking brake set - Engine idling - Mode control set to the outside air position - Blower control set to the high speed position - A/C set to the ON position - All windows open CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in a R-134a refrigerant system. 4. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line Hose/Line HVAC: Service and Repair Coupler-Refrigerant Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1). 4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting. 6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4). INSTALLATION 1. Clean any dirt or foreign material from the spring-lock type refrigerant line coupler. 2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6128 b. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak. 3. Install new O-rings (8) on the male half of the refrigerant line coupler. 4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Position the female half of the coupler over the male half of the coupler. 6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler. 7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler. 8. Install the secondary retaining clip (3) over connected coupler cage (5). 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6129 Hose/Line HVAC: Service and Repair Line-A/C Discharge REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the wire harness connector from the A/C pressure transducer (8). 4. Remove the nut (2) that secures the A/C discharge line (1) to the A/C condenser (3). 5. Disconnect the A/C discharge line from the A/C condenser and remove and discard the seal. 6. Install plugs in, or tape over the discharge line fitting and condenser inlet port. 7. Remove the nut (7) that secures the A/C discharge line to the A/C compressor (6). 8. Disconnect the A/C discharge line from the A/C compressor and remove and discard the seal. 9. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 10. Remove the A/C discharge line from the engine compartment. 11. If necessary, remove the A/C pressure transducer from the A/C discharge line. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6130 1. If removed, install the A/C pressure transducer (8) onto the A/C discharge line (1). 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the opened discharge line fitting and the inlet port on the A/C condenser (3). 4. Lubricate a new seal with clean refrigerant oil and install it onto the discharge line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Install the A/C discharge line onto the A/C condenser. 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 20 N.m (15 ft.lbs.). 7. Remove the tape or plugs from the opened fitting on the A/C discharge line and the outlet port on the A/C compressor (6). 8. Lubricate a new seal with clean refrigerant oil and install it onto the discharge line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C discharge line onto the A/C compressor. 10. Install the nut (7) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft.lbs.). 11. Connect the wire harness connector to the A/C pressure transducer. 12. Reconnect the negative battery cable. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6131 Hose/Line HVAC: Service and Repair Line-A/C Liquid Front Section REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing. 5. Remove the plastic cover from the condenser outlet stud. 6. Remove the nut (8) that secures the front section of the A/C liquid line (10) to the A/C condenser (7). 7. Disconnect the A/C liquid line from the A/C condenser and remove and discard the seal. 8. Disengage the A/C liquid line from the body retaining clips (1 and 9). 9. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line (4). 10. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the seal. 11. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser outlet port. 12. Remove the front section of the A/C liquid line from the engine compartment. INSTALLATION NOTE: The A/C liquid line is serviced in two sections. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6132 1. Position the front section of the A/C liquid line (10) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser outlet port. 3. Lubricate a new seal with clean refrigerant oil and install it onto the front liquid line spring-lock coupler fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (4). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. 6. Engage the A/C liquid line into the body retaining clips (1 and 9). 7. Lubricate a new seal with clean refrigerant oil and install it on the front liquid line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line to the outlet port of the A/C condenser (7). 9. Install the nut (8) that secures the A/C liquid line to the A/C condenser. Tighten the nut to 20 N.m (15 ft.lbs.). 10. Install the plastic cover onto the condenser outlet stud. 11. If equipped with a gasoline engine, install the air filter housing. 12. If equipped with the diesel engine, install the passenger side battery tray. 13. Reconnect the negative battery cable(s). 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Rear Section REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6133 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing. 5. Disengage the rear section of the A/C liquid line (4) from the body retaining clip (3). 6. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (10) to the rear section of the liquid line. 7. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the seal. 8. Remove the secondary retaining clip (5) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator inlet tube (6). 9. Using the proper A/C line disconnect tool, disconnect the A/C liquid line from the evaporator inlet tube and remove and discard the seal. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator inlet port. 11. Remove the rear section of the A/C liquid line from the engine compartment. INSTALLATION NOTE: The A/C liquid line is serviced in two sections. 1. Position the rear section of the A/C liquid line (4) into the engine compartment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6134 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator inlet tube (6). 3. Lubricate a new seal with clean refrigerant oil and install it on the rear liquid line spring-lock coupler fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the rear section of the A/C liquid line to the evaporator inlet tube. 5. Install the secondary retaining clip (5) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator inlet tube. 6. Engage the A/C liquid line into the body retaining clip (3). 7. Lubricate a new seal with clean refrigerant oil and install it on the front liquid line spring-lock coupler fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the rear section of the A/C liquid line to the front section of the liquid line (10). 9. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 10. If equipped with a gasoline engine, install the air filter housing. 11. If equipped with the diesel engine, install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6135 Hose/Line HVAC: Service and Repair Line-A/C Suction REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air filter housing cover. 4. Remove the nut (4) that secures the A/C suction line (5) to the A/C compressor (6). 5. Disconnect the A/C suction line from the A/C compressor and remove and discard the seal. 6. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 7. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the accumulator (5). 8. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator. 9. Remove the O-ring seals from the accumulator tube fitting and discard the seals. 10. Install plugs in, or tape over the opened suction line fitting and the accumulator outlet tube. 11. Remove the A/C suction line from the engine compartment. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6136 1. Position the A/C suction line (5) into the engine compartment. 2. Remove the tape or plugs from the opened fitting on the A/C suction line and the inlet port on the A/C compressor (6). 3. Lubricate a new seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the A/C suction line onto the A/C compressor. 5. Install the nut (4) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft.lbs.). 6. Remove the tape or plugs from the opened suction line fitting and the accumulator outlet tube. 7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the A/C suction line (6) to the spring-lock coupler (1) on the accumulator (5) and install the secondary retaining clip (7). 9. Install the air filter housing cover. 10. Reconnect the negative battery cable. 11. Evacuate the refrigerant system. 12. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation Housing Assembly HVAC: Description and Operation All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of the following: - HVAC housing - The HVAC housing consists of an upper housing (7) and a lower housing (10) that are attached together by screws and is mounted to the dash panel behind the instrument panel. The HVAC housing contains the heater core (9), A/C evaporator (15), blend-air and mode-air doors, and has mounting provisions for the air-door actuators (3, 5, 6 and 8), floor distribution duct (4), blower motor (13), blower motor resistor, foam seals (12, 14 and 16) and the HVAC wire harness (11). - Air inlet housing - The air inlet housing (1) is mounted to the right end of the HVAC housing and contains the recirculation-air door and has mounting provisions for the recirculation door actuator (2). The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air that is allowed to flow through, or around, the heater core. The dual zone heating A/C system uses two blend door actuators while the single zone system uses only one blend door actuator. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator(s), which moves the blend-air door(s). This allows an almost immediate control of the output air temperature of the system. The mode door actuator operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric door actuators are connected to the vehicle electrical system by the HVAC wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housings at the selected speed by use of the blower motor resistor. NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, evaporator temperature sensor, blend-air and mode-air doors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Air Inlet Housing Removal and Installation REMOVAL WARNING: - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door. 1. Remove the HVAC housing assembly. 2. Remove the recirculation door actuator (1) from the air inlet housing (2) and disconnect the HVAC wire harness (4) from the actuator. 3. Remove the two screws (3) that secure the rear of the air inlet housing to the top of the HVAC housing (5). 4. Release the two retaining clips (1) that secure the front of the air inlet housing (2) to the top of the HVAC housing (3) and remove the air inlet Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6142 housing. NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 5. If required, disassemble the air inlet housing. INSTALLATION NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 1. Position the air inlet housing (2) onto the top of the HVAC housing (3). 2. Engage the two retaining clips (1) that secure the front of the air inlet housing to the HVAC housing. 3. Install the two screws (3) that secure the rear of the air inlet housing (2) to the top of the HVAC housing (5). Tighten the screws to 2.2 N.m (20 in.lbs.). 4. Install the recirculation door actuator (1) onto the air inlet housing. 5. Connect the HVAC wire harness (4) to the recirculation door actuator. 6. Install the HVAC housing assembly. HVAC Housing - Removal and Installation REMOVAL WARNING: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6143 - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. 1. Recover the refrigerant from the refrigerant system. Refer to Heating and Air Conditioning/ Service and Repair/ Procedures. See: Service and Repair/Procedures 2. Drain the engine cooling system. Refer to Engine, Cooling and Exhaust/ Cooling System/ Service and Repair/ Procedures. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Disconnect and isolate the negative battery cable. 4. Disconnect the A/C liquid line and the A/C accumulator from the A/C evaporator. 5. Disconnect the heater hoses from the heater core tubes. 6. Remove the powertrain control module (PCM) to gain access to the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts. 7. Remove the instrument panel from the passenger compartment. Refer to Body and Frame/ Interior Trim/ Dashboard / Instrument Panel/ Service and Repair/ Procedures. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6144 8. Remove the bolt (5) that secures the HVAC housing (4) to the floor bracket (6). 9. Remove the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel (1). 10. Pull the HVAC housing assembly rearward and remove the housing assembly from the passenger compartment. 11. If required, remove the fresh air inlet (2) from the dash panel(1). INSTALLATION NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. 1. If removed, install the fresh air inlet (2) onto the dash panel (1). 2. Position the HVAC housing assembly (4) into the passenger compartment with the mounting studs and the condensate drain tube in their proper locations in the dash panel. 3. Install the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 6.2 N.m (55 in.lbs.). 4. Install the bolt (5) that secures the HVAC housing to the floor bracket (6). Tighten the bolt to 6.2 N.m (55 in.lbs.). 5. Install the instrument panel. Refer to Body and Frame/ Interior Trim/ Dashboard / Instrument Panel/ Service and Repair/ Procedures. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Install the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2). Tighten the nuts to 6.2 N.m (55 in.lbs.). 7. Install the powertrain control module (PCM). 8. Connect the heater hoses to the heater core tubes. 9. Connect the A/C liquid line and the A/C accumulator to the A/C evaporator. 10. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6145 11. If the heater core is being replaced, flush the cooling system. 12. Refill the engine cooling system. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6146 Housing Assembly HVAC: Overhaul Air Inlet Housing DISASSEMBLY NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door. 1. Remove the air inlet housing (1) from the HVAC housing and place it on a workbench. 2. Remove the two foam insulators (2) from the air inlet housing. 3. To remove the recirculation-air door (1) from the air inlet housing (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the air inlet housing and pull the actuator coupler out of the pivot shaft of the recirculation-air door. NOTE: If the seals on the air door is deformed or damaged, the air door must be replaced. 4. Remove the recirculation-air door from the air inlet housing. ASSEMBLY NOTE: If the seals on the air door is deformed or damaged, the air door must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6147 1. Position the recirculation-air door (1) into the air inlet housing (2). CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seat located in the air inlet housing. 2. Align the actuator coupler (3) with the recirculation-air door pivot shaft and install the coupler until the coupler retaining tabs are fully engaged to the air inlet housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the air inlet housing. 3. Install the two foam insulators (2) into the air inlet housing (1). 4. Install the air inlet housing onto the HVAC housing. HVAC Housing DISASSEMBLY NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6148 1. Remove the HVAC housing assembly and place it on a workbench. 2. Disconnect the HVAC wire harness connectors from the mode door actuators (1), blend door actuators (2) and the recirculation door actuator (3). 3. Remove the screws that secure the mode door actuators and the blend door actuators to the HVAC housing (5) and remove the actuators. 4. Remove the screws that secure the recirculation door actuator to the air inlet housing (4) and remove the actuator. 5. Disconnect the wire harness connectors (1 and 3) from the blower motor resistor (7) and the blower motor (2). 6. Remove the screws (4) that secure the blower motor to the HVAC housing (5) and remove the blower motor. 7. Remove the screws (6) that secure the blower motor resistor to the HVAC housing and remove the resistor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6149 8. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) and remove the HVAC wiring harness from the HVAC housing (4). 9. Remove the air inlet housing (3) from the HVAC housing. 10. Remove the two screws (1) that secure the panel/ floor door outlet (2) to the top of the HVAC housing (4). NOTE: If the foam seal on the panel/floor door outlet is deformed or damaged, it must be replaced. 11. Release the two retaining tabs (3) that secure the panel/floor door outlet to the front of the HVAC housing and remove the door outlet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6150 12. Remove the three screws (1) that secure the panel/floor door assembly (2) to the top of the HVAC housing (3) and remove the door assembly. 13. To remove the panel/floor-air doors (1) from the panel/floor door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the door plate and pull the actuator coupler out of the pivot shaft of the panel/floor-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 14. Remove the panel/floor-air doors from the panel/ floor door plate. NOTE: If the foam seal for the heater core tubes is deformed or damaged, the seal must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6151 15. Remove the foam seal from the heater core tubes. 16. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 17. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 18. Carefully pull the heater core out of the front of the HVAC housing. 19. Inspect all heater core foam seals and replace as required. 20. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 21. Remove the floor distribution duct from the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6152 22. Carefully disconnect the linkage rod (1) from the two blend-air door levers (2) located on the back of the HVAC housing (3). NOTE: If the foam seal for the evaporator condensate drain tube is deformed or damaged, the seal must be replaced. 23. Remove the foam seal (4) from the evaporator condensate drain tube (5). 24. Remove the fifteen screws (6) that secure the upper and lower HVAC housing halves together and separate the housing halves. 25. Release the three retaining tabs (1) that secure the lower blend door assembly (2) to the lower half of the HVAC housing (3) and remove the door assembly. 26. Release the three retaining tabs that secure the upper blend door assembly to the upper half of the HVAC housing and remove the door assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6153 27. To remove the blend-air doors (1) from each blend door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the door plate being serviced and pull the actuator coupler out of the pivot shaft of the blend-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 28. Remove the blend-air doors from the blend door plates. 29. Remove the defroster-air doors (1) from the lower half of the HVAC housing (2) by carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the housing and pull the actuator coupler out of the pivot shaft of the defroster-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 30. Remove the defroster-air doors from the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6154 31. Remove the insulator (1) from the A/C evaporator (5). 32. Remove the probe of the evaporator temperature sensor (2) from the fins of the A/C evaporator. NOTE: If the foam seal for the A/C evaporator tubes is deformed or damaged, the seal must be replaced. 33. Remove the foam seal (3) from the tubes of the A/C evaporator. NOTE: If the foam seal around the A/C evaporator is deformed or damaged, the seal must be replaced. 34. Carefully lift the A/C evaporator out of the upper half of the HVAC housing (4). ASSEMBLY 1. Carefully install the A/C evaporator (2) into the upper half of the HVAC housing (4). 2. Install the foam seal (3) onto the tubes of the A/C evaporator. 3. Install the probe of the evaporator temperature sensor (2) between the fins of the A/C evaporator. 4. Install the insulator (1) onto the bottom of the A/C evaporator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6155 5. Install the defroster-air doors (1) into the lower half of the HVAC housing (2). 6. Align the actuator coupler (3) with the defroster-air door pivot shaft and install the coupler into side of the HVAC housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the HVAC housing. 7. Install the blend-air doors (1) into each of the two blend door plates (2). 8. Align the actuator coupler (3) with each blend-air door pivot shaft and install the coupler into side of each blend door plate. Be sure to install each coupler with the coupler arm located between the two stop tabs on each blend door plate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6156 9. Position the lower blend door assembly (2) into the lower half of the HVAC housing (3) and fully engage the three retaining tabs (1). 10. Position the upper blend door assembly into the upper half of the HVAC housing and fully engage the three retaining tabs. NOTE: Route the wire lead for the evaporator temperature sensor into the opening located on the upper half of the HVAC housing prior to installing the lower half of the HVAC housing. 11. Position the two halves of the HVAC housing together (3). 12. Install the fifteen screws (6) that secure the two housing halves together. Tighten the screws to 2.2 N.m (20 in.lbs.). 13. Install the foam seal (4) onto the evaporator con-densate drain tube (5). 14. Connect the linkage rod (1) to the two blend-air door levers (2) located on the back of the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6157 15. Position the front floor distribution duct (2) to the bottom of the HVAC housing (3). 16. Install the screws (1) that secure the front floor distribution duct to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 17. Carefully install the heater core (3) into the front of the HVAC housing. 18. Position the heater core tube bracket (2) onto the HVAC housing. 19. Install the two screws (1) that secures the heater core bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 20. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 21. Install the foam seal onto the heater core tubes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6158 22. Install the panel/floor-air doors (1) into the panel/ floor door plate (2). 23. Align the actuator coupler (3) with the panel/floor-air door pivot shaft and install the coupler into side of the panel/floor door plate. Be sure to install the coupler with the coupler arm located between the two stop tabs on the door plate. 24. Position the panel/floor door assembly (2) onto the top of the HVAC housing (3). NOTE: Install the two door springs onto the retaining screws prior to installation. 25. Install the three screws (2) that secure the door assembly to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6159 26. Position the panel/floor door outlet (2) onto the top of the HVAC housing (3) and fully engage the two retaining tabs (3). 27. Install the two screws (1) that secure the panel/ floor door outlet to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 28. Install the air inlet housing (3) onto the top of the HVAC housing (4). 29. Install the HVAC wire harness (1) onto the HVAC housing. Make sure the wires are routed through all wiring retainers. 30. Connect the HVAC wire harness to evaporator temperature sensor (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6160 31. Position the blower motor resistor (7) and the blower motor (2) into the bottom of the HVAC housing (5). 32. Install the screws (4 and 6) that secure the blower motor resistor and the blower motor to the HVAC housing. Tighten the screws to 2.2 N.m (20 in.lbs.). 33. Connect the HVAC wire harness connectors (1 and 3) to blower motor resistor and the blower motor. 34. Position the recirculation door actuator (3) onto the air inlet housing (4) and install the retaining screws. Tighten the screws to 2.2 N.m (20 in.lbs.) . 35. Position the mode door actuators (1) and the blend door actuators (2) onto the HVAC housing (5) and install the retaining screws. Tighten the screws to 2.2 N.m (20 in.lbs.). 36. Connect the HVAC wire harness connectors to the actuators. 37. Install the HVAC housing assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CAPACITY Refer to the A/C Underhood Specification Label located in the engine compartment. 2004 Ram Gas ...................................................................................................................................................... .................................. 0.728kg (1.604 lbs.) 2004 Ram Diesel ............................................................. ....................................................................................................................... 0.850kg (1.873 lbs.) 2005 Ram Gas .................................................................................................................................... .................................................... 0.728kg (1.604 lbs.) 2005 Ram Diesel ........................................... ......................................................................................................................................... 0.850kg (1.873 lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6165 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6166 Refrigerant: Description and Operation The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6167 Refrigerant: Service and Repair WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Always refer to the underhood HVAC Specification Label for the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the underhood HVAC Specification Label. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH PRESSURE) VALVE AT THIS TIME. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Fill .................................................................................................................................. ............................................................ 6 oz (180 ml) Accumulator ......................................................................................................................................... ............................................................... 2 oz (60 ml) Condenser ........................................................................................................................................... ................................................................. 1 oz (30 ml) Evaporator ........................................................................................................................................... ................................................................ 2 oz (60 ml) Compressor ..................................................................................................................................... Drain and measure the oil from the old compressor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6172 Refrigerant Oil: Fluid Type Specifications Denso 10S17 Compressor .................................................................................................................. ........................................................... ND-8 PAG Oil Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6173 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the underhood A/C system specification tag). The Sanden SD-7 A/C compressor used in this vehicle is designed to use ND-15 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for the 5.9L Diesel engine. The Denso 10S17 A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for the 3.7L, 4.7L, 5.7L and 8.3L engines. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6174 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the underhood A/C System Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when an accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. When an A/C compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer-A/C Pressure (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6178 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10 ° C (50° F) due to the pressure/temperature relationship of the refrigerant.The A/C pressure transducer input to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The A/C pressure transducer is diagnosed using a DRBIII(R) scan tool. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6179 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6187 Compressor Clutch Relay: Description and Operation The A/C clutch relay (1) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay The A/C clutch relay is located in the integrated power module (IPM) in the engine compartment. The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input from the powertrain control module (PCM) or engine control module (ECM) (depending on engine application), to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (86) receives a ground input from the PCM/ECM through the A/C clutch relay control circuit only when the PCM/ECM electronically pulls the circuit to ground. - The coil battery terminal (85) receives a battery current input from PTC 1 in the IPM through a fused ignition switch output (run) circuit only when the ignition switch is in the On position. - The normally open terminal (87) provides a battery current output to the A/C clutch coil through the A/C clutch relay output circuit only when the A/C clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C clutch relay coil is de-energized. The A/C clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard micro-relay and for complete HVAC wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6188 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2). NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for A/C clutch relay location. 3. Remove the A/C clutch relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for A/C clutch relay location. 1. Position the A/C clutch relay into the receptacle of the integrated power module (IPM) (2). 2. Align the A/C clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6196 Left Side Engine Compartment And Hood Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6197 Sensor-Ambient Air Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6198 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6199 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6200 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The blower motor is controlled by a rotary-type blower motor switch (6), mounted in the A/C-heater control (1). The switch allows the selection of one of four different blower motor speeds and includes an Off position. The blower motor switch provides a ground path through the A/C-heater control. The blower motor switch directs the ground path through the appropriate blower motor resistor wires, as required to achieve the selected blower motor speed. The blower motor switch is diagnosed using a DRBIII(R) scan tool. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C-heater control must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Sensor-Evaporator Temperature Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 6210 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the A/C evaporator. The probe (1) for evaporator temperature sensor is attached to the evaporator coil fins. The wire lead (2) for evaporator temperature sensor is routed through an opening at the back of the HVAC housing and the connector (3) is attached to the HVAC wire harness. The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a DRBIII(R) scan tool. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 6211 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Remove the wire lead for the evaporator temperature sensor (2) from the retainer located on the HVAC housing (1) and disconnect the sensor connector from the HVAC wire harness (3). 3. Remove the lower half of the HVAC housing from the upper half of the HVAC housing to gain access to the A/C evaporator. 4. Carefully remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2). 5. Remove the wire lead of the evaporator temperature sensor (3) from the upper half of the HVAC housing (4). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 6212 1. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator (2). 2. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing (4). 3. Assemble the HVAC housing. 4. Install the wire lead of the evaporator temperature sensor (2) to the retainer located on the HVAC housing (1) and connect the sensor connector to the HVAC wire harness (3). 5. Install the HVAC housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer-A/C Pressure (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6216 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10 ° C (50° F) due to the pressure/temperature relationship of the refrigerant.The A/C pressure transducer input to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The A/C pressure transducer is diagnosed using a DRBIII(R) scan tool. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6217 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant system. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant. The high side service port is located on the A/C discharge line. The A/C pressure transducer is mounted on the high side service port. The low side service port is located on the accumulator. Both the high side and low side A/C service port valve cores are serviceable. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 6221 Service Port HVAC: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Typical A/C service port shown. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in or tape over the opened service port(s). INSTALLATION NOTE: Typical A/C service port shown. 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 6222 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. NOTE: The protective cap helps aid in service port sealing and helps protects the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 6. Install the protective cap (1) onto the service port. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System Any vehicle which is to be returned to use following a supplemental restraint deployment, must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring must be replaced. If the passenger airbag is deployed, the passenger airbag door must be replaced. The seat belt tensioners are deployed by the same signal that deploys the driver and passenger airbags and must also be replaced if either front airbag has been deployed. If a side curtain airbag has been deployed, the complete airbag unit, the headliner, as well as the upper A, B, and C-pillar trim must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a supplemental restraint deployment, which may or may not be obvious during a visual inspection. On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected following a side curtain airbag deployment. It is also critical that the mounting surfaces and/or mounting brackets for the Airbag Control Module (ACM) and the side impact sensors be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ACM and each impact sensor are used by the supplemental restraint system to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required. All other vehicle components should be closely inspected following any supplemental restraint deployment, but are to be replaced only as required by the extent of the visible damage incurred. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 6228 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams Air Bag: Diagrams Airbag - Passenger Squib Airbag - Side Curtain Left Airbag - Side Curtain - Right Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain Air Bag: Description and Operation Air Bag-Side Curtain Optional side curtain airbags are available for this model when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the "SRS - AIR-BAG" logo located on the headliner above each A-pillar, or above each B-pillar on quad cab models. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These air-bag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails (5). Each folded airbag cushion is contained within a long extruded plastic channel (8) that extends along the roof rail from the A-pillar (6) at the front of the vehicle to just behind the B-pillar (2) on standard cab models, and to just behind the C-pillar (2) on quad cab models. A long tether (7) extends down the A-pillar from the front of the airbag cushion, where it is retained to the pillar with plastic push-in routing clips and it is secured to the base of the A-pillar near the belt line with a screw. The hybrid-type inflator (3) for each airbag is secured to the roof rail at the rear of the airbag unit behind the B-pillar (standard cab) or C-pillar (quad cab), and is connected to the airbag cushion by a long tubular manifold (4). The inflator bracket and the extruded airbag cushion channel are located with plastic push-in fasteners to the roof rail, then secured with screws to spring nuts located in the roof rail. A two-wire take out of the body wire harness with a keyed and latched connector insulator (1) on the B-pillar (standard cab) or C-pillar (quad cab) connects directly to an integral receptacle on the inflator initiator. The body wire harness connects the airbag unit to the Airbag Control Module (ACM). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, faulty, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, and C-pillar trim, and all other visibly damaged components must be replaced. Each side curtain airbag is deployed individually by an electrical signal generated by the Airbag Control Module (ACM) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6238 compressed inert gas. When the ACM sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision. The front tether keeps the front portion of the side curtain bag taut, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion quickly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6239 Air Bag: Description and Operation Air Bag-Driver The color-keyed, injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the armature of the four-spoke steering wheel. All models have a chrome Dodge Ram emblem in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The airbag cushion, housing (5), and inflator (3) are secured within an integral receptacle molded into the back of the trim cover (4). The four vertical walls of this receptacle have a total of twelve small windows with blocking tabs that are engaged by twelve hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver air-bag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire has an eyelet terminal connector that is captured beneath a flanged nut on the upper right inflator mounting stud on the back of the housing. The horn switch feed pigtail wire has a black, molded plastic insulator (1) that is secured by an integral retainer in a locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out and connector of the steering wheel wire harness. Both horn switch wires are routed through an integral notch in the center of the upper edge of the airbag housing stamping. The airbag used in this model is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. A 71 centimeter (28 inch) diameter, radial deploying fabric cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing by four flanged hex nuts. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag unit cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag trim cover and horn switch unit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6240 may be disassembled from the driver airbag unit, and is available for separate service replacement. The multistage driver airbag is deployed by electrical signals generated by the Airbag Control Module (ACM) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ACM to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ACM sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6241 Air Bag: Description and Operation Air Bag-Passenger The rearward facing surface of the injection molded, thermoplastic passenger airbag door (1) is the most visible part of the passenger airbag. The passenger airbag door is located above the glove box opening on the instrument panel in front of the front seat passenger seating position. SRT-10 models also have a unique instrument panel trim bezel (3) with the SRT-10 logo secured to the lower edge of the airbag door (1). The upper and outboard edges of the airbag door (1) are secured with seven integral snap features (3) to the instrument panel base trim, while two screws secure the integral inboard mounting flange to the base trim, and four screws secure the lower mounting flange to the upper glove box opening Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6242 reinforcement integral to the instrument panel structural support. The passenger airbag door includes an air conditioning panel outlet and housing (2). The panel outlet housing features four snap features that secure it to the back of the airbag door and a mounting tab that is also secured with one screw to the upper glove box opening reinforcement. Located behind the passenger airbag door within the instrument panel is the passenger airbag unit. The passenger airbag housing (8) fits into a molded receptacle on the back of the airbag door, where six stamped hook formations on the upper and lower edges of the airbag housing are engaged in six small window openings on the upper and lower flanges of the receptacle to secure the airbag door to the airbag housing. The inboard airbag door fasteners and mounting flange are concealed beneath the instrument panel center bezel, while the lower fasteners and mounting flange are concealed beneath the instrument panel lower surround. The passenger airbag unit is secured by four screws through two front (7) and two rear (4) brackets integral to the base of the airbag housing to the instrument panel structural support. The passenger airbag unit used in this model is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. The passenger airbag unit consists of a stamped and welded metal housing, the airbag cushion, the airbag inflator initiators (6), and a stamped metal airbag and inflator retainer plate that is secured to the airbag housing with six studs and nuts. The airbag housing contains the airbag inflator and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion is used. The airbag inflator is a non-azide, pyrotechnic-type unit that is secured to and sealed within the airbag housing. A short four-wire pigtail harness with a keyed, yellow connector insulator (5) connects the two inflator initiators to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The passenger airbag includes the airbag door, the panel outlet housing and for SRT-10 models only, the instrument panel trim bezel. This unit cannot be repaired, and must be replaced if deployed, faulty, or in any way damaged. The multistage passenger airbag is deployed by electrical signals generated by the Airbag Control Module (ACM) through the passenger airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ACM to suit the monitored impact conditions by providing one of four delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ACM sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through vent holes within the fabric used to construct the back (instrument panel side) of the airbag cushion. Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status Air Bag: Service and Repair Airbag Squib Status Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this model are deployed by electrical signals generated by the Airbag Control Module (ACM) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used due to an airbag system fault; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are sure of complete deployment. Refer to the Hazardous Substance Control System for proper disposal procedures. Dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local, and federal regulations. 1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. 2. Turn the ignition switch to the On position. 3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver and/or passenger airbag squibs. NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the squibs were both live. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6245 Air Bag: Service and Repair Cleanup Procedure Following a supplemental restraint deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless paniculate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a supplemental restraint. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: TO AVOID PERSONAL INJURY OR DEATH, IF YOU EXPERIENCE SKIN IRRITATION DURING CLEANUP, RUN COOL WATER OVER THE AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITATION OF THE NOSE OR THROAT, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are sure of complete deployment. Refer to AIRBAG SQUIB STATUS. All damaged, faulty, or non-deployed supplemental restraints which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is faulty or damaged and non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to dispose of all non-deployed and deployed supplemental restraints in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed supplemental restraints from the vehicle. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6246 Air Bag: Service and Repair Air Bag-Side Curtain WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE SIDE CURTAIN AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE SIDE CURTAIN AIRBAG CUSHION AND THE HEAD-LINER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. NOTE: The following procedure is for replacement of a faulty or damaged side curtain airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the headliner from the vehicle. 3. Remove the screw (6) that secures the side curtain airbag tether retainer (5) to the base of the A-pillar near the belt line. 4. Disengage the two side curtain airbag tether plastic retainer clips (4) from the A-pillar. 5. Disconnect the body wire harness connector for the side curtain airbag (9) from the connector receptacle at the back of the airbag inflator. 6. Remove the four screws (standard cab) or six screws (quad cab) (3) that secure the side curtain airbag inflator and manifold tube brackets to the spring nuts (2) in the roof rail (1). 7. Grasp the extruded plastic side curtain airbag channel firmly and pull it straight away from the roof rail far enough to disengage all three (standard cab) or five (quad cab) plastic push-in fasteners (8) that secure it. 8. Remove the side curtain airbag (7) from the vehicle as a unit. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6247 1. Check to be certain that the four (standard cab) or six (quad cab) spring nuts (2) that secure the side curtain airbag inflator and manifold tube brackets are properly installed and in good condition in the roof rail (1). 2. Position the side curtain airbag (7) into the vehicle as a unit. 3. Align all three (standard cab) or five (quad cab) plastic push-in fasteners (8) that secure the extruded plastic side curtain airbag channel with their holes in the roof side rail and push them straight into the roof rail until they are fully seated. 4. Working from the rear of the vehicle to the front, install and tighten the four screws (standard cab) or six screws (quad cab) (3) that secure the side curtain airbag inflator and manifold tube brackets to the nuts in the roof rail. Tighten the screws to 5 N.m (40 in.lbs.). 5. Reconnect the body wire harness connector for the side curtain airbag (9) to the connector receptacle at the back of the airbag inflator. Be certain the connector is fully engaged and latched. 6. Engage the two side curtain airbag tether plastic retainer clips (4) into the A-pillar. 7. Install and tighten the screw (6) that secures the side curtain airbag tether retainer (5) to the base of the A-pillar near the belt line. Tighten the screw to 6 N.m (55 in.lbs.). 8. Reinstall the headliner into the vehicle. 9. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6248 Air Bag: Service and Repair Air Bag-Driver Removal and Installation NOTE: The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. REMOVAL WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the two screws (3) that secure the driver airbag (1) to the steering wheel armature (2). CAUTION: Do not pull on the horn switch feed pigtail wire to disengage the connector from the driver airbag housing or to disconnect the horn switch to steering wheel wire harness connection. Improper pulling on this pigtail wire or connection can result in damage to the horn switch membrane or feed circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6249 3. Pull the driver airbag (1) away from the steering wheel far enough to access the three electrical connections on the back of the airbag housing. 4. Disconnect the steering wheel wire harness connector for the horn switch (2) from the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle. Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators. 5. The clockspring driver airbag pigtail wire connectors (3) are secured by integral latches to the airbag inflator connector receptacles, which are located on the back of the driver airbag housing. Depress the latches on each side of the connector insulator and pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles. 6. Remove the driver airbag from the steering wheel. 7. If the driver airbag has been deployed, the clockspring must be replaced. INSTALLATION WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT AIRBAGS ARE SERVICED WITH TRIM COVERS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6250 1. Position the driver airbag (1) close enough to the steering wheel to reconnect the three electrical connections on the back of the airbag housing. 2. When installing the driver airbag, reconnect the two clockspring driver airbag pigtail wire connectors (3) to the airbag inflator connector receptacles by pressing straight in on the connector. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. You can be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place. 3. Reconnect the steering wheel wire harness connector (2) for the horn switch to the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. 4. Carefully position the driver airbag (1) in the steering wheel (2). Be certain that the clockspring pigtail wires and the steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel armature. 5. From the underside of the steering wheel, install and tighten the two screws (3) that secure the driver airbag to the steering wheel armature. Tighten the screws to 10 N.m (90 in.lbs.). 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Disassembly and Assembly WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6251 DAIMLER-CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. DISASSEMBLY 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver airbag from the steering wheel. 3. Place the driver airbag on a suitable clean and dry work surface with the trim cover facing down. If the trim cover will be reused, be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 4. Carefully pry the horn switch feed pigtail wire connector (1) away from the back of the driver airbag housing (3) far enough to disengage the integral connector retainer from the locator hole just above the upper right inflator mounting stud. 5. Remove the nut that secures the horn switch ground pigtail wire eyelet terminal (2) to the upper right inflator stud on the back of the driver airbag housing. 6. Remove the horn switch ground pigtail wire eyelet terminal from the upper right inflator stud on the back of the driver airbag housing. 7. Disengage each of the twelve hooks (5 and 6) of the airbag housing from the twelve windows in the vertical walls of the trim cover (4), one wall at a time. Start by disengaging the upper wall, then do each of the two side walls, and finish with the lower wall. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag housing firmly and evenly downward into the trim cover receptacle, while at the same time pushing outward on the upper edge of the receptacle wall. 8. With all of the hooks disengaged, lift the housing, inflator, and cushion as a unit from the receptacle on the back of the driver airbag trim cover. ASSEMBLY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6252 1. Place the driver airbag on a suitable work surface with the airbag cushion facing up. 2. Fold the two flaps (1) of cushion material up around the sides and over the top of the airbag cushion retainer strap (2). 3. Position the new driver airbag trim cover over the airbag cushion, then push the receptacle of the trim cover down evenly over the cushion. Be certain that the cushion material flaps remain oriented over the cushion retainer strap as they were in Step 2. 4. Turn the driver airbag and the new driver airbag trim cover over as a unit, and place the unit on a suitable clean and dry work surface with the airbag cushion facing down. Be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 5. Be certain that the horn switch feed and ground pigtail wires are routed through the clearance notch at the top of the airbag housing (3), between the housing and the upper vertical wall of the trim cover receptacle. 6. Work around the perimeter of the unit engaging each of the twelve hooks (5 and 6) on the driver airbag housing through the windows in the walls of the trim cover receptacle. 7. Install the horn switch ground pigtail wire eyelet terminal (2) over the upper right inflator stud on the back of the driver airbag housing. 8. Install and tighten the nut that secures the horn switch ground pigtail wire eyelet terminal to the upper right inflator stud on the back of the driver airbag housing. Tighten the nut to 7 N.m (65 in.lbs.). 9. Using hand pressure, push the integral retainer of the horn switch feed pigtail wire connector (1) into the locator hole just above the upper right inflator mounting stud on the back of the airbag housing. 10. After the driver airbag has been assembled, try pulling the trim cover and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6253 11. Before reinstalling the airbag onto the steering wheel, check that the blocking tab (1) in each of the trim cover windows is oriented over the airbag housing hook (4) as shown. 12. Reinstall the driver airbag onto the steering wheel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6254 Air Bag: Service and Repair Air Bag-Passenger NOTE: The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. REMOVAL WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the lower surround from the instrument panel. 3. Remove the screw (2) that secures the mounting tab of the panel outlet housing to the upper glove box opening reinforcement (3). 4. Remove the six screws (4) that secure the inboard and lower flanges of the passenger airbag door (1) to the instrument panel. 5. Reach through and above the glove box opening to access and remove the two screws (4) that secure the passenger airbag rear brackets to the upper glove box opening reinforcement (2). 6. Reach through and above the glove box opening to access and remove the two screws (3) that secure the passenger airbag front brackets to the instrument panel structural support. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6255 7. Using a trim stick (1) or another suitable wide flat-bladed tool, gently pry the upper and outboard edges of the passenger airbag door (2) away from the instrument panel (3) far enough to disengage the seven snap features on the door from the receptacles in the instrument panel base trim. 8. Pull the passenger airbag housing and door unit straight back from the instrument panel far enough to access the instrument panel wire harness take out and connector for the airbag located on the inboard side of the airbag housing. 9. Disconnect the passenger airbag pigtail wire connector from the instrument panel wire harness connector for the airbag. To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 10. Remove the passenger airbag and airbag door from the instrument panel as a unit. INSTALLATION WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - TO AVOID PERSONAL INJURY OR DEATH, THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG UNITS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE TRIM BEZEL ON THE LOWER EDGE OF THE PASSENGER AIRBAG DOOR ON SRT-10 MODELS MUST NEVER BE REMOVED OR TRANSFERRED TO ANOTHER PASSENGER AIRBAG DOOR. REPLACEMENT PASSENGER AIRBAG UNITS ARE SERVICED WITH DOORS THAT INCLUDE A REPLACEMENT TRIM BEZEL. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN TRIM BEZEL SEPARATION AND OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6256 1. Carefully position the passenger airbag and airbag door (1) to the instrument panel as a unit. 2. Reconnect the passenger airbag pigtail wire connector to the instrument panel wire harness connector for the airbag. This connector is secured to the inboard side of the airbag housing. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. 3. Position the passenger airbag housing and door unit into the instrument panel. 4. Using hand pressure, press firmly and evenly over each of the seven snap features on the upper and outboard edges of the passenger airbag door until they snap into their receptacles in the instrument panel base trim. 5. Reach through and above the glove box opening to install and tighten the two screws (3) that secure the passenger airbag front brackets to the instrument panel structural support. Tighten the screws to 6 N.m (55 in.lbs.). 6. Reach through and above the glove box opening to install and tighten the two screws (4) that secure the passenger airbag rear brackets to the upper glove box opening reinforcement (2). Tighten the screws to 6 N.m (55 in.lbs.). 7. Install and tighten the six screws (4) that secure the inboard and lower flanges of the passenger air-bag door (1) to the instrument panel. Tighten the screws to 2 N.m (20 in.lbs.). 8. Install and tighten the screw (2) that secures the mounting tab of the panel outlet housing to the upper glove box opening reinforcement (3). Tighten the screw to 2 N.m (20 in.lbs.). 9. Reinstall the lower surround onto the instrument panel. 10. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Fig.37 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6261 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6262 Air Bag Control Module: Connector Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6263 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6264 Standard Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6265 Quad Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6266 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6267 Module-Occupant Restraint Controller C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6268 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) (1) is also sometimes referred to as the Occupant Restraint Controller (ORC). The ACM is located below the instrument panel center stack in the passenger compartment of the vehicle, where it is secured by three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just forward of the instrument panel center support bracket. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electronic sating sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ACM housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ACM housing has integral mounting flanges on three corners. The mounting flange to the left of the connector receptacle has an integral locating pin on its lower surface. Both left side flanges have round mounting holes, while the flange on the right side has a slotted mounting hole. A molded plastic electrical connector (4) with two receptacles, one containing twenty-four terminal pins and the other containing thirty-two terminal pins, exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through two dedicated take outs and connectors of the instrument panel wire harness. The impact sensor and sating sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addition, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors a resistor multiplexed input from the passenger airbag on/off switch and provides a control output for the Off indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag on/off switch is set to the Off position, the ACM turns on the passenger airbag on/off switch Off indicator and will internally disable the passenger airbag from being deployed. The ACM also turns on the on/off switch Off indicator for about seven seconds each time the ignition switch is turned to the On position as a bulb test. Following the bulb test, the ACM controls the status of the Off indicator based upon the resistance of the input from the on/off switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag on/off switch circuits, and will turn on the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ACM to be operational whenever the ignition switch is in the Start or On positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or On positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6269 Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On models equipped with optional side curtain airbags, the ACM also monitors inputs from two remote side impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ACM to provide confirmation to the ACM microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact and the status of the passenger airbag on/off switch input, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. For vehicles equipped with the passenger airbag on/off switch, the passenger front airbag and seat belt tensioner will be deployed by the ACM only if enabled by the switch (passenger airbag on/off switch indicator Off) at the time of the impact. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus, and the electronic message inputs to and outputs from the ACM requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Module Air Bag Control Module: Service and Repair Module WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the two wire harness connectors (3 & 4) for the Airbag Control Module (ACM) (1) from the ACM connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ACM, depress the release tab and lift the lever arm on each connector. 5. From the left side of the floor panel transmission tunnel, reach behind the module to access and loosen the screw (2) that secures the right side of the ACM to the bracket (5) on the floor panel transmission tunnel. Loosen the screw about 7 millimeters (0.25 inch). 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pin on the bottom of the ACM mounting flange from the locating hole in the mounting bracket, then slide the ACM toward the left far enough to disengage the slotted hole in the right ACM mounting flange from under the head of the previously loosened right mounting screw. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 6272 1. Position the Airbag Control Module (ACM) (1) to the left side of the floor panel transmission tunnel near the ACM bracket (5). When the ACM is correctly positioned, the arrow on the ACM label will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted hole in the right ACM mounting flange under the head of the previously loosened right mounting screw (2), then engage the locating pin on the bottom of the left ACM mounting flange into the locating hole in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 N.m (9 ft.lbs.). 4. From the left side of the floor panel transmission tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screw to 12 N.m (9 ft.lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the two wire harness connectors (3 & 4) for the ACM to the ACM connector receptacle located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 6273 Air Bag Control Module: Service and Repair Cover WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover (2) away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (1). 3. Remove the ACM cover from the instrument panel. INSTALLATION 1. Position the ACM cover (2) to the instrument panel. 2. Align the snap clip retainer on each side of the ACM cover with the instrument panel receptacle (1) at each side of the center bracket on the floor panel transmission tunnel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6277 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6278 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6279 Right Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6280 Switch-Passenger Airbag On/Off Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6281 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator (3) visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate (2) and nomenclature, and the key cylinder actuator (4). The "Off" position of the switch is illuminated when this switch position is selected, while the "On" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger airbag is enabled. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ACM, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6282 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and face plate unit (3) to the back of the bezel. 4. Remove the passenger airbag on/off switch and face plate from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and face plate unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch face plate to the back of the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Clockspring C4 (Premium) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6286 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring assembly is secured with two screws onto the multi-function switch mounting housing near the top of the steering column behind the steering wheel. The clockspring consists of a flat, round molded plastic case (8) with a stubby tail that hangs below the steering column. The tail contains two connector receptacles that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor (10) with a large exposed hub. The upper surface of the rotor hub has a large center hole, two large flats, an engagement dowel with a yellow rubber boot (7), two short pigtail wires with connectors (1), and two connector receptacles (5) that face toward the steering wheel. The lower surface of the rotor hub has a molded plastic turn signal cancel cam (3) with two lobes that is keyed to the rotor and is secured there with four integral snap features. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles (4) that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that face the steering wheel. Service replacement clocksprings are shipped pre-centered and with a molded plastic locking pin (1) that snaps into a receptacle on the rotor and is engaged between two tabs on the upper surface of the rotor case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed from the clockspring after it is installed on the steering column. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this model the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches, if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate contact noise between the dowel and the steering wheel. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6287 Two short, yellow-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch feed pigtail wire connector and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering Clockspring Assembly / Spiral Cable: Service and Repair Clockspring Centering WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. 3. Rotate the clockspring rotor (10) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel and yellow rubber boot (7) should end up at the bottom, and the arrows on the clockspring rotor and case (9) should be in alignment. 5. The clockspring is now centered. Secure the clock-spring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. 6. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 6290 Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight ahead position. 2. Disconnect and isolate the battery negative cable. 3. Remove the driver airbag from the steering wheel. 4. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Remove the steering wheel from the steering column. 6. Remove the steering column opening cover from the instrument panel. 7. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 6291 8. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 9. Using hand pressure, push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 10. Remove the upper shroud from the lower shroud and the steering column. 11. Remove the one center screw that secures the lower shroud to the steering column (4). 12. Remove the lower shroud from the steering column. 13. Disconnect the two instrument panel wire harness connectors from the two connector receptacles located below the steering column on the back of the clockspring housing. 14. Remove the two screws (3) that secure the clock-spring to the multi-function switch mounting housing. 15. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. 16. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clock-spring must be centered again before it is reinstalled. INSTALLATION CAUTION: If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 6292 NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. While holding the centered clockspring rotor and case stationary in relation to each other, carefully slide the clockspring down over the steering column upper shaft. 2. Align and seat the hole in the locating tab (2) on the clockspring case over the locating pin on the multi-function switch mounting housing. 3. Install and tighten the two screws (3) that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 N.m (20 in.lbs.). 4. Reconnect the two instrument panel wire harness connectors to the two connector receptacles located below the steering column on the back of the clockspring housing. 5. Position the lower shroud (3) onto the steering column (4). 6. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 N.m (20 in.lbs.). 7. Position the upper shroud (1) onto the steering column over the lower shroud. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shroud halves. 8. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 9. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 6293 10. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 11. Reinstall the steering column opening cover onto the instrument panel. 12. If a new clockspring has been installed, remove the plastic locking pin that is securing the clock-spring rotor to the clockspring case to maintain clockspring centering. NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clock-spring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 13. Reinstall the steering wheel onto the steering column. 14. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 15. Reinstall the driver airbag onto the steering wheel. 16. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Standard Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6297 Standard Cab Right Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6298 Quad Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6299 Quad Cab Right Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6300 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Sensor-Side Impact-Right 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6301 Impact Sensor: Description and Operation Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain air-bags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Air-bag Control Module (ACM). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module (ACM). The ACM microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ACM. The impact sensors and the ACM communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ACM, and the electronic message communication between the sensors and the ACM requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab Impact Sensor: Service and Repair Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 6304 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 6305 Impact Sensor: Service and Repair Quad Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 6306 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation An airbag indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the airbag system, which is not available in some markets. The airbag indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The airbag indicator consists of a stencil-like cutout of the words "AIR BAG" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "AIR BAG" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The airbag indicator is serviced as a unit with the instrument cluster. The airbag indicator gives an indication to the vehicle operator when the airbag system is faulty or inoperative. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Airbag Control Module (ACM) over the Programmable Communications Interface (PCI) data bus. The airbag indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the airbag indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the airbag indicator is illuminated for about six seconds. The entire bulb test is a function of the ACM. - ACM Lamp-On Message - Each time the cluster receives a lamp-on message from the ACM, the airbag indicator will be illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-off message from the ACM, whichever is longer. - Communication Error - If the cluster receives no airbag messages for three consecutive seconds, the airbag indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the ACM. - Actuator Test - Each time the cluster is put through the actuator test, the airbag indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the airbag indicator is a function of the instrument cluster. The ACM continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ACM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the ACM sends a lamp-on message after the bulb test, it indicates that the ACM has detected a system malfunction and/or that the airbags and seat belt tensioners may not deploy when required, or may deploy when not required. The ACM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ACM of the condition, the instrument cluster and the ACM will each store a DTC, and the cluster will flash the seatbelt indicator on and off as a backup to notify the vehicle operator. For proper diagnosis of the airbag system, the ACM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the airbag indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Fig.37 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6315 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6316 Air Bag Control Module: Connector Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6317 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6318 Standard Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6319 Quad Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6320 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6321 Module-Occupant Restraint Controller C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6322 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) (1) is also sometimes referred to as the Occupant Restraint Controller (ORC). The ACM is located below the instrument panel center stack in the passenger compartment of the vehicle, where it is secured by three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just forward of the instrument panel center support bracket. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electronic sating sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ACM housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ACM housing has integral mounting flanges on three corners. The mounting flange to the left of the connector receptacle has an integral locating pin on its lower surface. Both left side flanges have round mounting holes, while the flange on the right side has a slotted mounting hole. A molded plastic electrical connector (4) with two receptacles, one containing twenty-four terminal pins and the other containing thirty-two terminal pins, exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through two dedicated take outs and connectors of the instrument panel wire harness. The impact sensor and sating sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addition, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors a resistor multiplexed input from the passenger airbag on/off switch and provides a control output for the Off indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag on/off switch is set to the Off position, the ACM turns on the passenger airbag on/off switch Off indicator and will internally disable the passenger airbag from being deployed. The ACM also turns on the on/off switch Off indicator for about seven seconds each time the ignition switch is turned to the On position as a bulb test. Following the bulb test, the ACM controls the status of the Off indicator based upon the resistance of the input from the on/off switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag on/off switch circuits, and will turn on the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ACM to be operational whenever the ignition switch is in the Start or On positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or On positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6323 Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On models equipped with optional side curtain airbags, the ACM also monitors inputs from two remote side impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ACM to provide confirmation to the ACM microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact and the status of the passenger airbag on/off switch input, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. For vehicles equipped with the passenger airbag on/off switch, the passenger front airbag and seat belt tensioner will be deployed by the ACM only if enabled by the switch (passenger airbag on/off switch indicator Off) at the time of the impact. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus, and the electronic message inputs to and outputs from the ACM requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module Air Bag Control Module: Service and Repair Module WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the two wire harness connectors (3 & 4) for the Airbag Control Module (ACM) (1) from the ACM connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ACM, depress the release tab and lift the lever arm on each connector. 5. From the left side of the floor panel transmission tunnel, reach behind the module to access and loosen the screw (2) that secures the right side of the ACM to the bracket (5) on the floor panel transmission tunnel. Loosen the screw about 7 millimeters (0.25 inch). 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pin on the bottom of the ACM mounting flange from the locating hole in the mounting bracket, then slide the ACM toward the left far enough to disengage the slotted hole in the right ACM mounting flange from under the head of the previously loosened right mounting screw. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 6326 1. Position the Airbag Control Module (ACM) (1) to the left side of the floor panel transmission tunnel near the ACM bracket (5). When the ACM is correctly positioned, the arrow on the ACM label will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted hole in the right ACM mounting flange under the head of the previously loosened right mounting screw (2), then engage the locating pin on the bottom of the left ACM mounting flange into the locating hole in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 N.m (9 ft.lbs.). 4. From the left side of the floor panel transmission tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screw to 12 N.m (9 ft.lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the two wire harness connectors (3 & 4) for the ACM to the ACM connector receptacle located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 6327 Air Bag Control Module: Service and Repair Cover WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover (2) away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (1). 3. Remove the ACM cover from the instrument panel. INSTALLATION 1. Position the ACM cover (2) to the instrument panel. 2. Align the snap clip retainer on each side of the ACM cover with the instrument panel receptacle (1) at each side of the center bracket on the floor panel transmission tunnel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation This model is equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The LATCH system provides for the installation of suitable child restraints in certain seating positions without using the standard equipment seat belt provided for that seating position. Standard cab models are equipped with a fixed-position child restraint upper tether anchor for the front center and outboard seating positions (2), and child restraint lower anchors for the front outboard seating position (1). Quad cab models are equipped with a fixed-position child restraint upper tether anchor strap for the rear center and both rear outboard seating positions (2), and child restraint lower anchors for both rear outboard seating positions (1). All front seat child restraint anchors are deleted on quad cab models. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6336 The two upper tether anchors (3) for standard cab models are integral to the upper cab back panel reinforcement and are concealed behind individual trim cover and bezel units (1) that are integral to the cab back trim panel (2). These upper tether anchors cannot be adjusted or repaired and, if faulty or damaged, they must be replaced as a unit with the upper cab back panel reinforcement. The upper tether anchor trim covers and bezels are serviced as a unit with the cab back trim panel. The three upper tether anchor straps (1) for quad cab models are secured to the upper cab back panel (2) reinforcement with screws (3). These anchor straps are concealed behind the upright rear seat back. The upper tether anchor straps are available for individual service replacement. The lower anchors (2) for all models are integral to their respective front or rear seat cushion frame. Round markers (3) with an imprinted child seat icon on the standard cab front seat back trim cover helps identify the anchor locations for that application because they may be otherwise difficult to see with the seat back in the upright position. These lower anchors are each constructed from round steel bar stock that is formed into a U-shape, then securely welded at each end to the seat cushion frame. They are each accessed from the front of their respective seats, at each side where the seat back meets the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6337 seat cushion. These lower anchors cannot be adjusted or repaired and, if faulty or damaged, they must be replaced as a unit with the seat cushion frame. On quad cab models, if the rear seat lower anchors (2) have been bent or broken as a result of a vehicle collision, the latch for the affected rear seat cushion frame unit must also be replaced. WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. See owner's manual in the vehicle glove box for more information on the proper use of all of the factory-installed child restraint anchors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6338 Child Seat Tether Attachment: Service and Repair TETHER STRAP WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The following procedure applies only to the rear seat upper child tether straps used on quad cab models. The child restraint anchors used in other models and locations are integral to other components and cannot be serviced separately. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (3) that secures the child tether strap (1) to the upper cab back panel (2) reinforcement. 3. Remove the child tether strap from the upper cab back panel reinforcement. INSTALLATION 1. Position the child tether strap (1) onto the cab back panel (2) upper reinforcement. 2. Install and tighten the screw (3) that secures the child tether strap to the upper cab back panel reinforcement. Tighten the screw to 14 N.m (10 ft.lbs.). 3. Reinstall the rear seat into the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation Seat Belt: Description and Operation AUTOMATIC LOCKING RETRACTOR The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanism for the passenger side front seating position is mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in the passenger side front seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the passenger side front seat belt and retractor unit and is concealed beneath a molded plastic cover located on the same side of the retractor spool as the seat belt tensioner housing. The retractor is secured to the inner B-pillar on the right side of the vehicle and is concealed beneath the molded plastic inner B-pillar trim. The automatic locking mechanism cannot be adjusted or repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The automatic locking mode of the retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make an audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Seat Belt: Service and Repair Seat Belt FRONT CENTER WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models also have a unique fixed position black, keyed front center seat belt lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. The following procedure also applies to the fixed position front center seat lap belt located on the right side of the front center seat section of all quad cab models. The three-point front center seat belt and retractor unit is only used on standard cab models. REMOVAL 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position for easiest access to the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle (1). 2. From behind the front seat, remove the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). 3. From the front of the front seat, reach between the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 4. Remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle from the front seat. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6344 1. From the front of the front seat, position the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle (1) between the center seat cushion (6) and the adjacent right or left front outboard seat cushion. 2. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to route the front center seat belt buckle, lap belt unit lower anchor, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 3. From behind the front seat, position the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the buckle or belt anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket. Tighten the screw to 40 N.m (29 ft.lbs.). 5. Move the adjacent right or left front outboard seat section (40 percent) back to its rearward position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6345 Seat Belt: Service and Repair Seat Belt & Retractor Front Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. REMOVAL 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6346 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. INSTALLATION 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N.m (29 ft.lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 N.m (15 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6347 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Move the front seat back to its rearward position. 10. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Standard Cab The seat belt retractor on the driver's side of standard cab models only includes a tension reducer. The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6348 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (7) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Remove the screw (8) that secures the lower seat belt anchor to the lower inner B-pillar (14). 5. Remove the lower seat belt anchor from the lower inner B-pillar. 6. Unsnap and remove the trim cover (5) from the front outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 7. Remove the screw that secures the seat belt turning loop to the height adjuster. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper (2) and lower (6) trim from the inner B-pillar. 10. Remove the screw (12) that secures the seat belt web guide (13) to the inner B-pillar near the belt line. 11. Remove the seat belt web guide from the inner B-pillar. 12. On the driver side only, disconnect the body wire harness take out and white connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor (10). 13. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 14. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (11) for the tensioner. 15. Remove the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. 16. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 17. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6349 1. Position the front outboard seat belt and retractor (10) to the retractor mounting hole in the lower inner B-pillar (14). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (11) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. On the driver side only, reconnect the body wire harness take out and white connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 7. Position the seat belt web guide (13) to its mounting location on the inner B-pillar near the belt line. 8. Install and tighten the screw (12) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 9. Reinstall the upper (2) and lower (6) trim onto the inner B-pillar. 10. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper inner B-pillar. 11. Install and tighten the screw (4) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Engage the lower snap features of the new trim cover (5) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 13. Position the lower seat belt anchor (7) to the lower inner B-pillar. 14. Install and tighten the screw (8) that secures the lower seat belt anchor to the B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 15. Reinstall the stowage tray onto the rear floor panel behind the seat. 16. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 17. Move the front seat back to its rearward position. Front Outboard - Quad Cab The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6350 IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model.The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (10) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar (3). 4. Remove the lower seat belt anchor from the floor panel near the base of the inner B-pillar. 5. Unsnap and remove the trim cover (6) from the front outboard seat belt turning loop (4) to access the screw (5) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 6. Remove the screw that secures the seat belt turning loop to the height adjuster. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper (2) and lower (8) trim from the inner B-pillar. 9. Remove the screw (14) that secures the seat belt web guide (15) to the inner B-pillar near the belt line. 10. Remove the seat belt web guide from the inner B-pillar. 11. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 12. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (13) for the tensioner. 13. Remove the screw (11) that secures the lower retractor (12) bracket to the lower inner B-pillar below the retractor mounting hole. 14. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 15. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6351 1. Position the front outboard seat belt and retractor (12) to the retractor mounting hole in the lower inner B-pillar (3). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (11) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (13) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. Position the seat belt web guide (15) to its mounting location on the inner B-pillar near the belt line. 7. Install and tighten the screw (14) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 8. Reinstall the upper (2) and lower (8) trim onto the inner B-pillar. 9. Position the seat belt turning loop (4) onto the height adjuster (1) on the upper inner B-pillar. 10. Install and tighten the screw (5) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 11. Engage the lower snap features of the new trim cover (6) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 12. Position the lower seat belt anchor (10) to the floor panel near the base of the inner B-pillar. 13. Install and tighten the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 14. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 15. Move the front seat back to its rearward position. Rear Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The rear center seat belt retractor is secured with a single screw to a mounting bracket that includes the unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle, but can be removed from the mounting bracket and is serviced separately from the two buckles. The center anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket. REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6352 1. Reach between the rear seat cushion and the rear seat back to access and unbuckle the center seat belt lower anchor latch plate (12) from the unique black, keyed center lower anchor buckle (10). Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Remove the rear seat from the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 3. Lift upward on the forward edge of the rear center seat belt bezel (3) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket (5). 4. Remove the bezel from the webbing of the rear center seat belt (2). 5. Lift the rear center seat belt cover (4) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 6. Remove the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket (7) on the upper cab back panel reinforcement. 7. Remove the belt bracket of the rear center seat belt from the body bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6353 8. Remove the screw (6) that secures the rear center seat belt retractor (3) to the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the cab back panel. 9. Remove the rear center seat belt retractor from the center anchor and right outboard occupant buckles and mounting bracket unit. 10. Remove the rear center seat belt and retractor unit from the vehicle. INSTALLATION 1. Position the rear center seat belt and retractor unit (3) onto the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the base of the cab back panel. 2. Install and tighten the screw (6) that secures the rear center seat belt retractor bracket to the center anchor and right outboard occupant buckles and mounting bracket unit. Tighten the screw to 40 N.m (29 ft.lbs.). 3. Position the belt bracket (5) of the rear center seat belt (2) onto the body bracket (7) on the upper cab back panel (1) reinforcement. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket. Tighten the screws to 20 N.m (15 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6354 5. Lift the webbing of the rear center seat belt and slide the cover (4) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (3) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Reach between the rear seat cushion and the rear seat back to buckle the rear center seat belt lower anchor latch plate (12) to the unique black, keyed center lower anchor buckle. Rear Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (9) that secures the lower seat belt anchor (8) to the base of the inner C-pillar (1). 3. Remove the lower seat belt anchor from the base of the inner C-pillar. 4. Unsnap and remove the trim cover (5) from the rear outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the upper inner C-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 5. Remove the screw that secures the seat belt turning loop to the C-pillar. 6. Remove the seat belt turning loop from the upper inner C-pillar. 7. Remove the upper and lower trim (2) from the inner C-pillar. 8. Remove the screw (7) that secures the seat belt web guide (12) to the inner C-pillar near the belt line. 9. Remove the seat belt web guide from the inner C-pillar. 10. Remove the screw (10) that secures the lower retractor bracket (11) to the lower inner C-pillar below the retractor mounting hole. 11. Disengage the hook on the upper retractor bracket from the slot in the lower inner C-pillar above the retractor mounting hole. 12. Remove the rear outboard seat belt and retractor from the retractor mounting hole in the lower inner C-pillar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6355 INSTALLATION 1. Position the rear outboard seat belt and retractor (11) to the retractor mounting hole in the lower inner C-pillar (1). 2. Engage the hook on the upper retractor bracket into the slot in the lower inner C-pillar above the retractor mounting hole. 3. Install and tighten the screw (10) that secures the lower retractor bracket to the lower inner C-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Position the seat belt web guide (12) to the inner C-pillar near the belt line. 5. Install and tighten the screw (7) that secures the seat belt web guide to the inner C-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 6. Reinstall the upper and lower trim (2) onto the inner C-pillar. 7. Position the seat belt turning loop (3) onto the upper inner C-pillar. 8. Install and tighten the screw (4) that secures the seat belt turning loop to the C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 9. Engage the lower snap features of the new trim cover (5) over the rear outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 10. Position the lower seat belt anchor (8) to the base of the inner C-pillar. 11. Install and tighten the screw (9) that secures the lower seat belt anchor to the base of the inner C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Reinstall the rear seat into the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard Seat Belt Buckle: Service and Repair Front Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all models. The seat belt buckle on the driver's side front seat for all models also includes a seat belt switch. REMOVAL 1. Move the right or left front outboard seat section (2) to its most rearward position and tilt the seat back forward for easiest access to the front outboard seat belt buckle lower anchor. 2. For easiest access to the front outboard seat belt buckle lower anchor on standard cab models, also move the outboard seat section opposite the side from which the buckle is to be removed to its most forward position and tilt the seat back forward. 3. On standard cab models only, remove the stowage tray from the rear floor panel behind the seat. 4. From behind the front seat on the driver side only, disconnect the seat belt switch pigtail wire (3) connector from the seat wire harness take out and connector for the switch located below the inboard edge of the driver side inboard seat track (4) just forward of the buckle lower anchor. 5. From behind the front seat, remove the screw (5) that secures the front outboard seat belt buckle (1) lower anchor to the bracket on the inboard seat track. 6. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to access and remove the front outboard seat belt buckle from the seat. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6360 1. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion (2) to position the front outboard seat belt buckle (1) to the seat. Be certain to engage the anti-rotation tab on the buckle anchor into the corresponding hole in the inboard seat track bracket. 2. From behind the front seat, install and tighten the screw (5) that secures the front outboard seat belt buckle lower anchor to the bracket on the inboard seat track (4). Tighten the screw to 25 N.m (18 ft.lbs.). 3. From behind the front seat on the driver side only, reconnect the seat belt switch pigtail wire (3) connector to the seat wire harness take out and connector for the switch located below the inboard edge of the driver side inboard seat track just forward of the buckle lower anchor. 4. On standard cab models only, reinstall the stowage tray onto the rear floor panel behind the seat. 5. On standard cab models, move the outboard seat section opposite the side from which the buckle was replaced to its most rearward position and tilt the seat back to its upright position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6361 Seat Belt Buckle: Service and Repair Front Center and Center Anchor WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models also have a unique fixed position black, keyed front center seat belt lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. The following procedure also applies to the fixed position front center seat lap belt located on the right side of the front center seat section of all quad cab models. The three-point front center seat belt and retractor unit is only used on standard cab models. REMOVAL 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position for easiest access to the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle (1). 2. From behind the front seat, remove the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). 3. From the front of the front seat, reach between the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 4. Remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle from the front seat. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6362 1. From the front of the front seat, position the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle (1) between the center seat cushion (6) and the adjacent right or left front outboard seat cushion. 2. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to route the front center seat belt buckle, lap belt unit lower anchor, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 3. From behind the front seat, position the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the buckle or belt anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket. Tighten the screw to 40 N.m (29 ft.lbs.). 5. Move the adjacent right or left front outboard seat section (40 percent) back to its rearward position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6363 Seat Belt Buckle: Service and Repair Rear Center and Left Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. REMOVAL 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (3) that secures either the center (5) or the left outboard (4) occupant buckle unit to the rear floor panel (7) near the base of the cab back panel (1). On models with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 3. Remove the center or the left outboard occupant buckle unit from the rear floor panel or from the rear seat mounting bracket. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6364 1. Position the center (5) or the left outboard (4) occupant buckle unit onto the rear floor panel (7) or onto the rear seat mounting bracket near the base of the cab back panel (1). On models with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 2. Install and tighten the screw (3) that secures the center or the left outboard occupant buckle unit to the rear floor panel. Tighten the screw to 40 N.m (29 ft.lbs.). 3. Lower the rear seat cushion back to its normal seating position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6365 Seat Belt Buckle: Service and Repair Rear Center Anchor and Right Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket. The rear center seat belt retractor is also secured to the mounting bracket with these two buckles, but can be removed from the mounting bracket and is serviced separately from the two buckles. REMOVAL 1. Reach between the rear seat cushion and the rear seat back to access and unbuckle the rear center seat belt lower anchor latch plate from the unique black, keyed lower anchor center buckle (5). Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Remove the rear seat from the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 3. Remove the screw (6) that secures the rear center seat belt retractor (3) to the center anchor and right outboard occupant buckles (1) and mounting bracket (4) unit on the rear floor panel near the cab back panel. 4. Remove the rear center seat belt retractor from the center anchor/right outboard occupant buckle and mounting bracket unit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6366 5. Remove the two screws (3) that secure the center anchor/right outboard occupant buckles and mounting bracket unit to the rear floor panel (7) near the base of the cab back panel(1). 6. Remove the center anchor/right outboard occupant buckles and mounting bracket unit from the rear floor panel. INSTALLATION 1. Position the center anchor and right outboard occupant buckles and mounting bracket unit (6) onto the rear floor panel (7) near the base of the cab back panel (1). 2. Install and tighten the two screws (3) that secure the center anchor and right outboard occupant buckles and mounting bracket unit to the rear floor panel. Tighten the screws to 40 N.m (29 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 6367 3. Position the rear center seat belt retractor (3) onto the center anchor (5) and right outboard (1) occupant buckles and mounting bracket (4) unit. 4. Install and tighten the screw (6) that secures the rear center seat belt retractor to the center anchor and right outboard occupant buckles and mounting bracket unit. Tighten the screw to 40 N.m (29 ft.lbs.). 5. Reinstall the rear seat into the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 6. Reach between the rear seat cushion and the rear seat back to access and buckle the rear center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track (4). The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire (3) and connector on the seat belt buckle-half (1), which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion (2) in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Page 6371 Seat Belt Buckle Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty front seat belt buckle-half assembly. 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G301) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams Seat Belt Height Adjuster: Diagrams Motor-Seat Adjuster-Driver Horizontal Motor-Seat Adjuster-Front Driver Vertical Motor-Seat Adjuster-Front Passenger Vertical Motor-Seat Adjuster-Passenger Horizontal Motor-Seat Adjuster-Rear Passenger Vertical Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams > Page 6375 Motor-Seat Adjuster-Rear Passenger Vertical Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams > Page 6376 Seat Belt Height Adjuster: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. REMOVAL 1. Unsnap and remove the trim cover from the front outboard seat belt turning loop to access the screw that secures the turning loop to the height adjuster (2) on the upper inner B-pillar (1). Discard the removed turning loop trim cover as it is not intended for reuse. 2. Remove the screw that secures the seat belt turning loop to the height adjuster. 3. Remove the front seat belt turning loop from the height adjuster. 4. Remove the upper trim from the inner B-pillar. 5. Loosen the two screws (3) that secure the seat belt turning loop height adjuster far enough to remove the adjuster from the upper B-pillar. 6. Disengage the tab near the lower end of the seat belt turning loop height adjuster from the slot in the sheet metal and remove the adjuster from the inner B-pillar. INSTALLATION 1. Position the front seat belt turning loop adjuster (2) to the inner B-pillar (1). 2. Engage the tab near the lower end of the seat belt turning loop height adjuster into the slot in the sheet metal of the inner B-pillar. 3. Hand tighten the lower of the two screws (3) that secure the seat belt turning loop height adjuster to the upper B-pillar far enough to keep the tab on the lower end of the adjuster engaged in the B-pillar slot. 4. Install the upper screw that secures the seat belt turning loop height adjuster to the upper B-pillar, then tighten both the upper and lower screws to 40 N.m (29 ft.lbs.). 5. Reinstall the upper trim onto the inside of the B-pillar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams > Page 6377 6. Position the seat belt turning loop onto the height adjuster on the upper inner B-pillar. 7. Install and tighten the screw that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 8. Engage the lower snap features of the new trim cover over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the Off position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about sixty seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 13 kilometers-per-hour (8 miles-per-hour), the seatbelt indicator will begin to cycle between flashing on and off for five seconds, then lighting solid for three seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for twelve complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Airbag Control Module (ACM), store a Diagnostic Trouble Code (DTC) in the cluster memory, then flash the seatbelt indicator on and off. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The seatbelt switch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, refer to testing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming Seat Belt Reminder Lamp: Service and Repair Enhanced Seatbelt Reminder Programming The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The beltminder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming > Page 6383 Seat Belt Reminder Lamp: Service and Repair Customer Programming Sequence NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. 1. With the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except On or Start to toggle the beltminder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation Seat Belt Retractor: Description and Operation AUTOMATIC LOCKING RETRACTOR The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanism for the passenger side front seating position is mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in the passenger side front seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the passenger side front seat belt and retractor unit and is concealed beneath a molded plastic cover located on the same side of the retractor spool as the seat belt tensioner housing. The retractor is secured to the inner B-pillar on the right side of the vehicle and is concealed beneath the molded plastic inner B-pillar trim. The automatic locking mechanism cannot be adjusted or repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The automatic locking mode of the retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make an audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front Front Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. REMOVAL 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6389 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. INSTALLATION 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N.m (29 ft.lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 N.m (15 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6390 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Move the front seat back to its rearward position. 10. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Quad Cab The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model.The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6391 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (10) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar (3). 4. Remove the lower seat belt anchor from the floor panel near the base of the inner B-pillar. 5. Unsnap and remove the trim cover (6) from the front outboard seat belt turning loop (4) to access the screw (5) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 6. Remove the screw that secures the seat belt turning loop to the height adjuster. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper (2) and lower (8) trim from the inner B-pillar. 9. Remove the screw (14) that secures the seat belt web guide (15) to the inner B-pillar near the belt line. 10. Remove the seat belt web guide from the inner B-pillar. 11. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 12. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (13) for the tensioner. 13. Remove the screw (11) that secures the lower retractor (12) bracket to the lower inner B-pillar below the retractor mounting hole. 14. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 15. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6392 1. Position the front outboard seat belt and retractor (12) to the retractor mounting hole in the lower inner B-pillar (3). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (11) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (13) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. Position the seat belt web guide (15) to its mounting location on the inner B-pillar near the belt line. 7. Install and tighten the screw (14) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 8. Reinstall the upper (2) and lower (8) trim onto the inner B-pillar. 9. Position the seat belt turning loop (4) onto the height adjuster (1) on the upper inner B-pillar. 10. Install and tighten the screw (5) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 11. Engage the lower snap features of the new trim cover (6) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 12. Position the lower seat belt anchor (10) to the floor panel near the base of the inner B-pillar. 13. Install and tighten the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 14. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 15. Move the front seat back to its rearward position. Front Outboard - Standard Cab The seat belt retractor on the driver's side of standard cab models only includes a tension reducer. The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6393 CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (7) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Remove the screw (8) that secures the lower seat belt anchor to the lower inner B-pillar (14). 5. Remove the lower seat belt anchor from the lower inner B-pillar. 6. Unsnap and remove the trim cover (5) from the front outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 7. Remove the screw that secures the seat belt turning loop to the height adjuster. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper (2) and lower (6) trim from the inner B-pillar. 10. Remove the screw (12) that secures the seat belt web guide (13) to the inner B-pillar near the belt line. 11. Remove the seat belt web guide from the inner B-pillar. 12. On the driver side only, disconnect the body wire harness take out and white connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor (10). 13. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 14. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (11) for the tensioner. 15. Remove the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. 16. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 17. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6394 1. Position the front outboard seat belt and retractor (10) to the retractor mounting hole in the lower inner B-pillar (14). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (11) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. On the driver side only, reconnect the body wire harness take out and white connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 7. Position the seat belt web guide (13) to its mounting location on the inner B-pillar near the belt line. 8. Install and tighten the screw (12) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 9. Reinstall the upper (2) and lower (6) trim onto the inner B-pillar. 10. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper inner B-pillar. 11. Install and tighten the screw (4) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Engage the lower snap features of the new trim cover (5) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 13. Position the lower seat belt anchor (7) to the lower inner B-pillar. 14. Install and tighten the screw (8) that secures the lower seat belt anchor to the B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 15. Reinstall the stowage tray onto the rear floor panel behind the seat. 16. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 17. Move the front seat back to its rearward position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6395 Seat Belt Retractor: Service and Repair Rear Rear Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The rear center seat belt retractor is secured with a single screw to a mounting bracket that includes the unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle, but can be removed from the mounting bracket and is serviced separately from the two buckles. The center anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket. REMOVAL 1. Reach between the rear seat cushion and the rear seat back to access and unbuckle the center seat belt lower anchor latch plate (12) from the unique black, keyed center lower anchor buckle (10). Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Remove the rear seat from the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 3. Lift upward on the forward edge of the rear center seat belt bezel (3) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket (5). 4. Remove the bezel from the webbing of the rear center seat belt (2). 5. Lift the rear center seat belt cover (4) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 6. Remove the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket (7) on the upper cab back panel reinforcement. 7. Remove the belt bracket of the rear center seat belt from the body bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6396 8. Remove the screw (6) that secures the rear center seat belt retractor (3) to the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the cab back panel. 9. Remove the rear center seat belt retractor from the center anchor and right outboard occupant buckles and mounting bracket unit. 10. Remove the rear center seat belt and retractor unit from the vehicle. INSTALLATION 1. Position the rear center seat belt and retractor unit (3) onto the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the base of the cab back panel. 2. Install and tighten the screw (6) that secures the rear center seat belt retractor bracket to the center anchor and right outboard occupant buckles and mounting bracket unit. Tighten the screw to 40 N.m (29 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6397 3. Position the belt bracket (5) of the rear center seat belt (2) onto the body bracket (7) on the upper cab back panel (1) reinforcement. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket. Tighten the screws to 20 N.m (15 ft.lbs.). 5. Lift the webbing of the rear center seat belt and slide the cover (4) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (3) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Reach between the rear seat cushion and the rear seat back to buckle the rear center seat belt lower anchor latch plate (12) to the unique black, keyed center lower anchor buckle. Rear Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6398 1. Remove the rear seat from the vehicle. 2. Remove the screw (9) that secures the lower seat belt anchor (8) to the base of the inner C-pillar (1). 3. Remove the lower seat belt anchor from the base of the inner C-pillar. 4. Unsnap and remove the trim cover (5) from the rear outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the upper inner C-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 5. Remove the screw that secures the seat belt turning loop to the C-pillar. 6. Remove the seat belt turning loop from the upper inner C-pillar. 7. Remove the upper and lower trim (2) from the inner C-pillar. 8. Remove the screw (7) that secures the seat belt web guide (12) to the inner C-pillar near the belt line. 9. Remove the seat belt web guide from the inner C-pillar. 10. Remove the screw (10) that secures the lower retractor bracket (11) to the lower inner C-pillar below the retractor mounting hole. 11. Disengage the hook on the upper retractor bracket from the slot in the lower inner C-pillar above the retractor mounting hole. 12. Remove the rear outboard seat belt and retractor from the retractor mounting hole in the lower inner C-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6399 1. Position the rear outboard seat belt and retractor (11) to the retractor mounting hole in the lower inner C-pillar (1). 2. Engage the hook on the upper retractor bracket into the slot in the lower inner C-pillar above the retractor mounting hole. 3. Install and tighten the screw (10) that secures the lower retractor bracket to the lower inner C-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Position the seat belt web guide (12) to the inner C-pillar near the belt line. 5. Install and tighten the screw (7) that secures the seat belt web guide to the inner C-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 6. Reinstall the upper and lower trim (2) onto the inner C-pillar. 7. Position the seat belt turning loop (3) onto the upper inner C-pillar. 8. Install and tighten the screw (4) that secures the seat belt turning loop to the C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 9. Engage the lower snap features of the new trim cover (5) over the rear outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 10. Position the lower seat belt anchor (8) to the base of the inner C-pillar. 11. Install and tighten the screw (9) that secures the lower seat belt anchor to the base of the inner C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Reinstall the rear seat into the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Seat Belt-Tension Reducer-Driver (Standard Cab) Seat Belt-Tensioner-Driver Seat Belt-Tensioner-Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tension Reducer Seat Belt Tensioner: Description and Operation Seat Belt Tension Reducer A seat belt tension reducer (5) is standard equipment for the driver side front outboard seat belt on standard cab versions of this model. The tension reducer is integral to the driver side front outboard seat belt and retractor unit, which is secured to the inner B-pillar on the left side of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tension reducer consists primarily of a 12-volt Direct Current (DC) solenoid and an integral connector receptacle (6) that is located on the forward facing end housing of the retractor. The seat belt tension reducer is controlled by a battery current output of the ignition switch and a ground path provided by the seat belt switch, and is connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tension reducer cannot be repaired and, if faulty or damaged, the entire driver side front outboard seat belt and retractor unit must be replaced. The seat belt tension reducer is controlled by a ground signal received from the seat belt switch on the seat belt switch sense circuit and a battery current signal received from the ignition switch on the fused ignition switch output (run-accessory) circuit. When the seat belt switch is closed (the driver side front seat belt is fastened) and the ignition switch is in the On or Accessory positions, the seat belt tension reducer solenoid is energized. When the solenoid is energized, it actuates a mechanism within the driver side front outboard seat belt retractor to reduce the normal recoil spring tension exerted by the retractor spool, which is designed to reel in the seat belt webbing onto the spool. When the driver side seat belt is unbuckled or if the ignition switch is turned to any position except On or Accessory, the tension reducer solenoid is de-energized and the normal recoil spring tension of the retractor is restored. The action of the seat belt tension reducer results in improved seat belt comfort for the driver. Reducing the seat belt retractor recoil spring tension is desirable on standard cab models of this vehicle and not on the quad cab model due to the different mounting position required for the seat belt turning loop on the B-pillar relative to the driver's seat position on the standard cab model. The seat belt tension reducer may be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tension Reducer > Page 6405 Seat Belt Tensioner: Description and Operation Seat Belt Tensioner Front outboard seating position seat belt tensioners supplement the driver and passenger airbags for all versions of this model. The seat belt tensioner is integral to the front outboard seat belt and retractor units, which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a die cast aluminum tensioner housing or chamber (1), a mechanical clutch unit, a tape-like metal strip, a pair of cutters, a pyrotechnically activated gas generator (2), and a short pigtail wire (3). All of these components are located on one side of the retractor spool on the outside of the retractor housing. The seat belt tensioners are controlled by the Airbag Control Module (ACM) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if faulty or damaged, the entire outboard front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A locked retractor that will not allow the seat belt webbing to be retracted or extracted is a sure indication that the seat belt tensioner has been deployed and requires replacement. The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Airbag Control Module (ACM) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ACM sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed at the top of the tensioner housing which contains a long metal tape that is routed through two chambers within the housing. Each end of the tape is wound around the outer sleeve of a mechanical clutch mechanism secured to one end of the torsion bar upon which the retractor spool is secured. As the gas expands, it is directed against the metal tape within the two chambers of the housing causing the tape to unwind from the clutch sleeve. As the clutch rotates it engages the torsion bar, which drives the seat belt retractor spool causing the slack to be removed from the seat belt. Once a seat belt tensioning sequence has been completed, the forward momentum of the occupant results in deformation of the torsion bar. As the torsion bar deforms it allows the seat belt webbing to unwind from the retractor spool, which causes the metal tape to be wound back onto the clutch sleeve until it is pulled tight against two cutter blades within the housing, which immediately cut the metal tape. Removing excess slack from the seat belt not only keeps the occupant properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of a harmful contact with the steering wheel, steering column, instrument panel and/or windshield. Also, the torsion bar is designed to deform in order to control the loading being applied to the occupant by the seat belt during a frontal impact, further reducing the potential for occupant injuries. The ACM monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. For proper diagnosis of the seat belt tensioners, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6406 Seat Belt Tensioner: Testing and Inspection SEAT BELT TENSION REDUCER The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt tension reducer from the tension reducer connector receptacle on the driver side front outboard seat belt and retractor unit. Using an ohmmeter, measure the resistance between the seat belt switch sense circuit terminal pin and the fused ignition switch output (run-accessory) circuit terminal pin in the tension reducer connector receptacle on the retractor. Resistance through the tension reducer solenoid coil should be 53 ohms at 20° C (68° F). If OK, go to Step 2. If not OK, replace the faulty driver side front outboard seat belt and retractor unit. 2. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt tension reducer and a good ground. There should be continuity with the driver side front seat belt buckled, and no continuity with the driver side front seat belt unbuckled. If OK, go to Step 3. If not OK, repair the shorted or open seat belt switch sense circuit between the tension reducer and the seat belt switch as required. 3. Reconnect the battery negative cable. Check for battery current at the fused ignition switch output (run-accessory) circuit of the body wire harness connector for the seat belt tension reducer. There should be battery current with the ignition switch in the On or Accessory positions, and no battery current with the ignition switch in any other position. If not OK, repair the shorted or open fused ignition switch output (run-accessory) circuit between the tension reducer and the ignition switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6411 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6412 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6413 Right Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6414 Switch-Passenger Airbag On/Off Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6415 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator (3) visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate (2) and nomenclature, and the key cylinder actuator (4). The "Off" position of the switch is illuminated when this switch position is selected, while the "On" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger airbag is enabled. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ACM, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6416 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and face plate unit (3) to the back of the bezel. 4. Remove the passenger airbag on/off switch and face plate from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and face plate unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch face plate to the back of the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Standard Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6420 Standard Cab Right Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6421 Quad Cab Left Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6422 Quad Cab Right Side Body Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6423 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Sensor-Side Impact-Right 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6424 Impact Sensor: Description and Operation Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain air-bags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Air-bag Control Module (ACM). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module (ACM). The ACM microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ACM. The impact sensors and the ACM communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ACM, and the electronic message communication between the sensors and the ACM requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab Impact Sensor: Service and Repair Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 6427 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 6428 Impact Sensor: Service and Repair Quad Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 6429 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track (4). The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire (3) and connector on the seat belt buckle-half (1), which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion (2) in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Page 6433 Seat Belt Buckle Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty front seat belt buckle-half assembly. 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G301) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Revised Antenna Mast Installation Antenna Mast: Technical Service Bulletins Audio System - Revised Antenna Mast Installation NUMBER: 08-058-05 GROUP: Electrical DATE: October 29, 2005 SUBJECT: Revised Radio Antenna Mast Installation Procedure MODELS: 2005 - 2006 (DR/DH/D1) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (ND) Dakota 2005 - 2006 (PL) Neon 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan DISCUSSION: The installation procedure for the radio antenna mast has been revised. Please use the following procedure when installing the antenna mast to the antenna base. CAUTION: Do not exceed the torque specification in the step below. Damage to the antenna mast and/or base may occur if the tightening torque is exceeded. 1. Install antenna mast to antenna base. Finger tighten the antenna mast until it is fully seated on antenna base; no gap between the mast and base. Using a torque wrench, tighten the antenna mast to 3.4 - 3.6 N.m (30 - 32 in.lbs.) (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. 3. Remove the radio. 4. Remove the antenna mounting fasteners. 5. Cut each end of the cable (1) and leave remaining portion in the instrument panel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Page 6443 1. Position new antenna cable to wire harness. Secure into place. 2. Install antenna mounting fasteners. 3. Install radio. 4. Install instrument panel top cover. 5. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Diagrams Antenna Cable: Diagrams Antenna Cable - Satellite Radio No.1 Antenna Cable - Satellite Radio No.2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation Alarm Module: Description and Operation The Sentry Key Immobilizer Module (SKIM) (1) is the primary component of the Sentry Key Immobilizer System (SKIS). This module contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKIM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKIM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKIM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. The Sentry Key Immobilizer Module (SKIM) transmits Radio Frequency (RF) signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM) for gasoline engines or the Engine Control Module (ECM) for diesel engines, the ElectroMechanical Instrument Cluster (EMIC) and/or a diagnostic scan tool. The SKIM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKIM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM or ECM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the transponder in the ignition key. The SKIM then listens for a return RF signal from the transponder. If the SKIM receives an RF signal with a valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM/ECM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM or ECM is an invalid key. Therefore, if no message is received from the SKIM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6452 The SKIM also sends electronic messages to the EMIC which control the VTSS indicator. The SKIM sends messages to the EMIC to turn the indicator on for about three seconds when the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the indicator off for a duration of about one second. Then the SKIM sends messages to turn the indicator on or off based upon the results of the SKIS self-tests. If the VTSS indicator comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the On position, it sends messages to flash the VTSS indicator. The SKIM can also send messages to flash the indicator and to generate a single audible chime whenever the Customer Learn programming mode is being utilized. The SKIS will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. For diagnosis or initialization of the SKIM and the PCM/ECM, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6453 Alarm Module: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6454 8. Disconnect the wire harness connector (2) from the Sentry Key Immobilizer Module (SKIM) (1). 9. Remove the screw (3) that secures the SKIM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKIM. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6455 1. Position the Sentry Key Immobilizer Module (SKIM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKIM to the steering column housing. Tighten the screw to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the SKIM (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6456 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.) 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.) 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 10. Reconnect the battery negative cable. NOTE: If the SKIM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Each ignition key (4) used in the Sentry Key Immobilizer System (SKIS) has an integral transponder chip (2) concealed beneath the molded rubber cap (1), where it is secured within a plastic mount in the head (3) of the metal key. In addition to having to be cut to match the mechanical coding of the ignition lock cylinder, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key Immobilizer Module (SKIM) to be recognized as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If faulty or damaged, the entire key and transponder unit must be replaced. When the ignition switch is turned to the On position, the Sentry Key Immobilizer Module (SKIM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKIM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKIM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKIM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKIM to the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKIM over the PCI data bus, the engine will be disabled after about two seconds of operation. The ElectroMechanical Instrument Cluster (EMIC) will also respond to the invalid key message on the PCI data bus by flashing the security indicator on and off. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKIM. Once the Sentry Key learns the Secret Key code of the SKIM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store key-related fault information in the form of Diagnostic Trouble Code (DTC) in SKIM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6464 Module-Sentry Key Immobilizer (SKIM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6465 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6466 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6467 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Testing and Inspection Keyless Entry Transmitter Battery: Testing and Inspection NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation A security indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is electronically disabled. This indicator is located in the lower right quadrant of the instrument cluster, between the speedometer and the coolant temperature gauge. The security indicator consists of a small round cutout in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or is armed. On models equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, hard wired inputs to the cluster from the various security system components, electronic messages received by the cluster from the Remote Keyless Entry (RKE) module over a dedicated serial bus, and electronic messages received by the cluster from the Sentry Key Immobilizer Module (SKIM) over the Programmable Communications Interface (PCI) data bus. The security indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. Depending upon the programmed condition he indicator can be illuminated solid, flashed at a slow rate (0.5 Hertz, 12.5 percent duty cycle), or flashed at a fast rate (1 Hertz, 50 percent duty cycle). The instrument cluster will turn on the security indicator for the following reasons: Bulb Test - On vehicles equipped with the optional SKIS, each time the ignition switch is turned to the On position the SKIM tells the cluster to illuminate the security indicator for about two seconds as a bulb test. - VTSS Indication - During the sixteen second VTSS arming function, the cluster will flash the security indicator on and off repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the cluster flashes the security indicator on and off continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. The security indicator will also flash at the fast rate to indicate that the VTSS has been triggered and is currently alarming. If the VTSS has alarmed until the alarm timed out and then rearmed itself, the cluster will flash the security indicator at a steady, slow rate for about thirty seconds after the VTSS is disarmed. - SKIS Lamp-On Message - Each time the cluster receives a lamp-on message from the SKIM, the security indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKIM message. The indicator remains illuminated solid or continues to flash until the cluster receives a SKIS lamp-off message from the SKIM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - On vehicles equipped with the optional SKIS, if the cluster receives no SKIS lamp-on or lamp-off messages from the SKIM for twenty consecutive seconds, the security indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid SKIS lamp-on or lamp-off message is received from the SKIM. - Actuator Test - Each time the instrument cluster is put through the actuator test, the security indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster circuitry controls the security indicator whenever the ignition switch is in the Off position and the VTSS is arming, armed, or alarming. Whenever the ignition switch is in the On or Start positions, the SKIM performs a self-test to decide whether the SKIS is in good operating condition and whether a valid key is present in the ignition lock cylinder. The SKIM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the security indicator or the instrument cluster circuitry that controls the indicator, refer to testing. If the instrument cluster flashes the security indicator upon ignition On, or turns on the security indicator solid after the bulb test, it indicates that a SKIS malfunction has occurred or that the SKIS is inoperative. For proper diagnosis of the VTSS, the SKIS, the SKIM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the security indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Diagrams Receiver-Satellite Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Diagrams > Page 6479 Cellular Phone Transceiver: Description and Operation The satellite receiver for the regular cab is located behind the center seat on the floor. The satellite receiver for the quad cab is located in the right rear corner of the cab, on the floor. The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery feed circuits and CAN bus messages. It will operate with the ignition key in the run or accessory position only. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab Cellular Phone Transceiver: Service and Repair Regular Cab REMOVAL NOTE: If the owner s satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Place front passenger seat in the forward position. 3. Remove the mounting fasteners. 4. Disconnect the antenna cable and electrical harness connectors. 5. Remove the satellite receiver. INSTALLATION NOTE: If the owner s satellite service was active before the satellite receiver was replaced, the new satellite receiver will have to be activated. The existing satellite receiver will have to be deactivated before the replacement satellite receiver can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab > Page 6482 1. Connect antenna cable and electrical harness connector to receiver. 2. Position module and install mounting fasteners. Tighten fasteners. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab > Page 6483 Cellular Phone Transceiver: Service and Repair Quad Cab REMOVAL NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Remove the mounting fasteners. 3. Disconnect the antenna cable and electrical harness connectors. 4. Remove the satellite receiver. INSTALLATION NOTE: If the owner's satellite service was active before the satellite receiver was replaced, the new satellite receiver will have to be activated. The existing satellite receiver will have to be deactivated before the replacement satellite receiver can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab > Page 6484 1. Connect antenna cable and electrical harness connector to receiver. 2. Position receiver and install mounting fasteners. Tighten fasteners. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 Module-Electronic Overhead (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 EOM System Schematic Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console Driver/Vehicle Information Display: Description and Operation Overhead Console An overhead console is available on this vehicle and includes the following components: - Front map/reading lamps - A blue-green vacuum-fluorescent display screen - if equipped with trip computer - Universal transmitter - if equipped - Electronic Overhead Module (EOM) The overhead console assembly is mounted by two snap clips and screws securing it to a molded plastic retainer bracket located above the headliner. The EOM is accessed by removing the overhead console from the bracket and pulling it away from the headliner. COMPASS DISPLAY All the available overhead consoles on this model include Compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle at 5 to 8 kilometers-per-hour (3 to 5 miles-per-hour), on level ground in a square shaped pattern. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing procedure may be required to restore proper compass operation. TEMPERATURE DISPLAY All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules, (CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the module over the Programmable Communications Interface (PCI) data bus circuit. For more information on the ambient temperature sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 6513 Driver/Vehicle Information Display: Description and Operation Universal Transmitter The universal transmitter transceiver is integral to the overhead console (7). The only visible component of the universal transmitter are the three transmitter push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as part of the Electronic Overhead Module (EOM). This unit includes the push button switches for both the transmitter and compass mini trip computer. The universal transmitter operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transmitter radio frequency codes to operate garage door openers, security gates and security lighting. The overhead console display provides visual feedback to the driver, showing which transmitter button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the transmitter system to enter the home. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console Driver/Vehicle Information Display: Testing and Inspection Overhead Console If the problem with the overhead console is an inaccurate or scrambled display, refer to SELFDIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 3. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Integrated Power Module (IPM), repair the open fused B(+) circuit as required. 3. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 4. If not OK, repair the open or shorted circuit as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the electronics module and the PCI data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 6516 Driver/Vehicle Information Display: Testing and Inspection Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - PCI data bus Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required PCI bus messages are present on the PCI bus. If all required messages are present on the PCI bus, or if the ignition switch is turned to the Off position, the EOM will automatically return to normal operation. The required PCI bus messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine Off Duration message - Ambient Air Temperature message NOTE: - The Fuel Used message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 6517 Driver/Vehicle Information Display: Testing and Inspection Universal Transmitter Radio Frequency Detector #9001 If both the Transmitter and the compass mini trip computer display are inoperative, refer to testing for further diagnosis. If the Universal Transmitter is inoperative, but the compass mini trip computer display is operating normally. Retrain the Transmitter with a known good transmitter as instructed and test the Transmitter operation again. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the universal transmitter assembly. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6520 Driver/Vehicle Information Display: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6521 Driver/Vehicle Information Display: Service and Repair Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6522 Driver/Vehicle Information Display: Service and Repair Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6523 Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6524 until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Erasing Transmitter Codes NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink is now in the train (or learning) mode and can be programmed at any time beginning with "Programming. Reprogramming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. To program a device to HomeLink using a HomeLink button previously trained, follow these steps: 1. Press and hold the desired HomeLink button. Do NOT release the button. 2. The EVIC display will show "Channel X Transmit" (where X is Channel 1, 2, or 3) for 20 seconds and then change to "Channel X Training". Without releasing the HomeLink button, proceed to step 3. 3. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 4. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6525 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6530 Motor-Adjustable Pedals (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6531 Pedal Positioning Motor: Description and Operation MOTOR - ADJUSTABLE PEDALS DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals. Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (1). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or for ward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable. The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor (1) nor drive mechanism are subject to the mechanical stress of brake or accelerator application. ^ SYSTEM FEATURES: Range of Adjustment: The pedals may be adjusted up to 3 inches (75 mm) - Pedal Adjustment Speed: 0.5 inch/seconds (12.5 mm/seconds) - Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is activated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6532 Pedal Positioning Motor: Service and Repair MOTOR - ADJUSTABLE PEDALS REMOVAL 1. Disconnect the negative battery cable. 2. Remove the kneeblocker. 3. Remove the brake light switch and discard. 4. Disconnect the adjustable pedal cables from the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission. 5. Disconnect the electrical connector. 6. Unclip the cable fasteners to the support. 7. Remove the one mounting bolt (2) for the adjustable pedal motor (1). 8. Remove the adjustable pedal motor (1) with the cables. NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. INSTALLATION NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. 1. Install the adjustable pedal motor (1) with the cables. 2. Install the one mounting bolt (2) for the adjustable pedal motor (1). 3. Clip the cable fasteners to the support. 4. Reconnect the electrical connector. 5. Reconnect the adjustable pedal cables to the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission. 6. Install the new brake light switch. 7. Install the kneeblocker. 8. Reconnect the negative battery cable. 9. Check for proper operation of the pedals. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 6539 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 6540 Starter-Adjustable Pedals (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 6541 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Amplifier - Radio C1 (Premium) Amplifier - Radio C2 (Premium) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6546 Amplifier - Subwoofer (SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6547 Amplifier: Description and Operation The optional Infinity premium speaker system includes a separate Infinity audio power amplifier. The amplifier is an eight-channel unit rated at 368 total output watts. The amplifier is located behind the glove box. If equipped, an additional amplifier rated at 140 watts is located under the center passenger seat. The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs through six separate channels with dedicated feed and return circuits to the individual speakers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Instrument Panel Mounted Amplifier: Service and Repair Instrument Panel Mounted REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove glove box. 3. Remove instrument panel center bezel. 4. Remove instrument panel lower right center bezel. 5. Disconnect electrical harness connector (4) from amplifier (2) 6. Remove mounting bolts (3) and amplifier. INSTALLATION 1. Connect electrical harness connector (4) and install amplifier (2). 2. Install and tighten mounting bolts (3). 3. Install instrument panel lower right center bezel. 4. Install instrument panel center bezel. 5. Install glove box. 6. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Instrument Panel Mounted > Page 6550 Amplifier: Service and Repair Center Seat Mounted REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise center seat cushion to access amplifier. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove amplifier. INSTALLATION 1. Connect electrical harness connector and position amplifier. 2. Install and tighten mounting fasteners. 3. Lower center seat. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static Radio Receiver: Customer Interest Audio System - Satellite Radio Static NUMBER: 08-055-05 GROUP: Electrical DATE: October 19, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER CONNECTOR PARTS OR PERFORM ANY ACTIONS RELATED TO CS, KJ, LH, PT, RS, WK and XK VEHICLES UNTIL NOVEMBER 28, 2005. SUBJECT: Satellite Radio Intermittent Static OVERVIEW: This bulletin involves replacing the Satellite Digital Audio Receiver (SDAR). MODELS: 2005 (CS) Pacifica 2005 (DR) Ram Truck 2004-2005 (HB) Durango 2005 (JR) Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2004 (LH) 300M 2005 (LX) 300/Magnum 2005 (ND) Dakota 2003 - 2005 (PT) Chrysler PT Cruiser 2005 (RS) Town & Country/Caravan 2005 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with a satellite radio receiver (sales code RSA or RSB) or dealer installed MOPAR satellite radio receiver part numbers 05064002A* and 05064020A*. SYMPTOM/CONDITION: The vehicle operator describes extreme static over the satellite radio audio (only when in the satellite mode) to the point of almost completely covering the intended audio. The static occurs at vehicle start-up, or the first time the radio is put into the satellite mode on a key cycle. The static will last the entire key cycle. This issue is completely intermittent, and in the next key cycle, operation may go back to normal. DIAGNOSIS: Due to the intermittent nature of the condition, demonstration of the issue is difficult. If the vehicle operator description is similar to the Symptom/Condition explained above, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 6560 PARTS REQUIRED: REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Antenna Module/Removal/Receiver-Satellite to remove the SDAR and separate it from it mounting bracket. NOTE: In the near future, the TechCONNECT path to the SDAR procedures will change. Receiver-Satellite will have its own heading under Audio. 2. CS, KJ, LH , PT, RS, WK and XK vehicles go to step 4. DR, HB, JR and ND go step 3. LX vehicles require the SDAR mounting bracket to be modified as follows: a. Place a drop of paint or correction fluid (white out) on the top of each of the (3) SDAR mounting studs of the replacement SDAR. b. Position the SDAR mounting studs against the SDAR mounting bracket so the wiring connectors of the SDAR are facing toward the front of the vehicle when the SDAR/bracket assembly is mounted in the vehicle and the mounting stud opposite the SDAR wiring connectors is 3/16 in. inboard of the crease in the SDAR mounting bracket, (Fig. 1) c. Drill 5/16 in. (8 mm) holes in the SDAR mounting bracket at the three locations marked by the paint. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 6561 3. For DR, HB, JR, LX and ND vehicles, remove the left locating key (when viewed with the SDAR mounting studs facing you) on the tan connector of the SDAR. The key can be shaved off using a utility knife or similar device, (Fig. 2). Continue with step 8. 4. Slide the red lock on the blue connector housing of the antenna harness to its unlock position. 5. Use a small screwdriver to pull up on the tab uncovered by the lock. 6. Slide the housing off the connector terminal. 7. Replace the removed blue connector housing and red lock with the "tan" colored housing, p/n 05189968AA and white lock p/n 05189969AA. 8. Record the Electronic Serial Number (ESN) of the removed and replacement SDAR's, (Fig. 3). 9. Install the appropriate replacement SDAR to the mounting bracket, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). 10. Tape back the original white connector to the antenna harness to prevent rattling. This white connector will NOT be used with the new SDAR. 11. Connect the antenna connector to the tan connector on the new SDAR. Insert the 12-way connector to the module. NOTE: Be sure to route the SDAR wiring so that is has no bends with a radius of less than 1 in. and is free of contact with the mounting bracket, tape, foam or convolute may be used to isolate the wiring if necessary. 12. Install the SDAR/bracket assembly into the vehicle, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 6562 NOTE: When activating the new SDAR, the vehicle must be in open sky with no obstructions over the antenna. 13. The new SDAR MUST be activated to be able to receive satellite programs. The customer's Sirrus account number or phone number, customer's complete address, and the ESN of the original and new SDAR are required. The ESN is on the SDAR itself, (Fig. 3), or can be retrieved through the radio. With both ESN's, the customer's Sirrus account number or phone number, customer's complete address in hand, call Sirrus at 888-539-7474, (to skip the recordings, press 1 then 3 and 3 again). Explain the transfer that needs to take place when the Sirrus agent answers. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static Radio Receiver: All Technical Service Bulletins Audio System - Satellite Radio Static NUMBER: 08-055-05 GROUP: Electrical DATE: October 19, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER CONNECTOR PARTS OR PERFORM ANY ACTIONS RELATED TO CS, KJ, LH, PT, RS, WK and XK VEHICLES UNTIL NOVEMBER 28, 2005. SUBJECT: Satellite Radio Intermittent Static OVERVIEW: This bulletin involves replacing the Satellite Digital Audio Receiver (SDAR). MODELS: 2005 (CS) Pacifica 2005 (DR) Ram Truck 2004-2005 (HB) Durango 2005 (JR) Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2004 (LH) 300M 2005 (LX) 300/Magnum 2005 (ND) Dakota 2003 - 2005 (PT) Chrysler PT Cruiser 2005 (RS) Town & Country/Caravan 2005 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with a satellite radio receiver (sales code RSA or RSB) or dealer installed MOPAR satellite radio receiver part numbers 05064002A* and 05064020A*. SYMPTOM/CONDITION: The vehicle operator describes extreme static over the satellite radio audio (only when in the satellite mode) to the point of almost completely covering the intended audio. The static occurs at vehicle start-up, or the first time the radio is put into the satellite mode on a key cycle. The static will last the entire key cycle. This issue is completely intermittent, and in the next key cycle, operation may go back to normal. DIAGNOSIS: Due to the intermittent nature of the condition, demonstration of the issue is difficult. If the vehicle operator description is similar to the Symptom/Condition explained above, perform the Repair Procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 6568 PARTS REQUIRED: REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Antenna Module/Removal/Receiver-Satellite to remove the SDAR and separate it from it mounting bracket. NOTE: In the near future, the TechCONNECT path to the SDAR procedures will change. Receiver-Satellite will have its own heading under Audio. 2. CS, KJ, LH , PT, RS, WK and XK vehicles go to step 4. DR, HB, JR and ND go step 3. LX vehicles require the SDAR mounting bracket to be modified as follows: a. Place a drop of paint or correction fluid (white out) on the top of each of the (3) SDAR mounting studs of the replacement SDAR. b. Position the SDAR mounting studs against the SDAR mounting bracket so the wiring connectors of the SDAR are facing toward the front of the vehicle when the SDAR/bracket assembly is mounted in the vehicle and the mounting stud opposite the SDAR wiring connectors is 3/16 in. inboard of the crease in the SDAR mounting bracket, (Fig. 1) c. Drill 5/16 in. (8 mm) holes in the SDAR mounting bracket at the three locations marked by the paint. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 6569 3. For DR, HB, JR, LX and ND vehicles, remove the left locating key (when viewed with the SDAR mounting studs facing you) on the tan connector of the SDAR. The key can be shaved off using a utility knife or similar device, (Fig. 2). Continue with step 8. 4. Slide the red lock on the blue connector housing of the antenna harness to its unlock position. 5. Use a small screwdriver to pull up on the tab uncovered by the lock. 6. Slide the housing off the connector terminal. 7. Replace the removed blue connector housing and red lock with the "tan" colored housing, p/n 05189968AA and white lock p/n 05189969AA. 8. Record the Electronic Serial Number (ESN) of the removed and replacement SDAR's, (Fig. 3). 9. Install the appropriate replacement SDAR to the mounting bracket, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). 10. Tape back the original white connector to the antenna harness to prevent rattling. This white connector will NOT be used with the new SDAR. 11. Connect the antenna connector to the tan connector on the new SDAR. Insert the 12-way connector to the module. NOTE: Be sure to route the SDAR wiring so that is has no bends with a radius of less than 1 in. and is free of contact with the mounting bracket, tape, foam or convolute may be used to isolate the wiring if necessary. 12. Install the SDAR/bracket assembly into the vehicle, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 6570 NOTE: When activating the new SDAR, the vehicle must be in open sky with no obstructions over the antenna. 13. The new SDAR MUST be activated to be able to receive satellite programs. The customer's Sirrus account number or phone number, customer's complete address, and the ESN of the original and new SDAR are required. The ESN is on the SDAR itself, (Fig. 3), or can be retrieved through the radio. With both ESN's, the customer's Sirrus account number or phone number, customer's complete address in hand, call Sirrus at 888-539-7474, (to skip the recordings, press 1 then 3 and 3 again). Explain the transfer that needs to take place when the Sirrus agent answers. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation Radio/Stereo Noise Filter: Description and Operation Radio noise suppression devices are Installed on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing," "hissing," "popping," "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Factory-installed radio noise suppression is accomplished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: - Engine-to-body ground strap - This length of braided ground strap has an eyelet terminal connector crimped to each end. One end is secured to the engine cylinder head(s). The other is secured to the plenum at the exhaust heat shield forward/outer attaching stud. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and Electro-Magnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Bed to Cab Radio/Stereo Noise Filter: Service and Repair Bed to Cab REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts and strap. INSTALLATION 1. Install the ground strap (3) and mounting fasteners (4). 2. Tighten mounting fasteners. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Bed to Cab > Page 6576 Radio/Stereo Noise Filter: Service and Repair Engine to Heat Shield REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts (2) from the cylinder heads. 3. Remove nut (3) from heat shield (1) and remove strap (2). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Bed to Cab > Page 6577 1. Install the mounting fastener (3) and ground strap (2) to the heat shield (1). 2. Tighten mounting fastener. 3. Install the retaining bolt and ground strap to the engine cylinder heads. 4. Tighten the retaining bolts. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6581 Remote Switch: Diagrams Switch-Remote Radio-Left Switch-Remote Radio-Right Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6582 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6583 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control MUX circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control MUX circuit to the Integrated Power Module (IPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6584 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Speaker-Instrument Panel-Center (Premium) Speaker-Instrument Panel-Left Speaker-Instrument Panel-Right Speaker-Left Front Door Speaker-Left Rear Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6588 Speaker-Right Front Door Speaker-Right Rear Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Standard Speaker: Description and Operation Standard The standard equipment speaker system includes speakers in four locations. One 15.2 X 22.8 centimeter (6X9 inch) full-range speaker is located in each front door. There is also one full-range 13.3 centimeter (5.25 inch) diameter full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Standard > Page 6591 Speaker: Description and Operation Premium The optional premium speaker system features eleven Premium model speakers in seven locations. Each of the standard speakers is replaced with Premium model speakers. One 8.8 centimeter (3.50 inch) diameter speaker is located on each end of the instrument panel top pad. One 6.3 centimeter (2.50 inch) diameter speaker is located in the center of the instrument panel top pad. One 15.2 X 22.8 centimeter (6X9 inch) Premium speaker is located in each front door. There is also one coaxial 13.3 centimeter (5.25 inch) diameter Premium full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). The premium speaker system also includes a power amplifier mounted behind the glove box. The total available power of the premium speaker system is 368 watts. If equipped, a 25.4 centimeter (10 inch) subwoofer is located behind the center passenger seat along with a amplifier (rated at 150 watts) located under the center passenger seat. The total available power if equipped with the subwoofer and second power amplifier is 518 watts. Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 6592 Speaker: Testing and Inspection Any diagnosis of the Audio system should begin with the use of a scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio and/or amplifier may result. 1. If all speakers are inoperative, check the fuses in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the IPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If vehicle is equipped with an amplifier, disconnect wire harness connector at output side of amplifier. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6595 Speaker: Service and Repair Instrument Panel Center Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6596 Speaker: Service and Repair Instrument Panel End Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6597 Speaker: Service and Repair Rear Cab Side Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6598 Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. Instrument Panel Center Speaker REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6599 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Instrument Panel End Speaker REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6600 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Rear Cab Side Speaker REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6601 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. Rear Door Speaker REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6602 1. Disconnect and isolate the battery negative cable. 2. Remove rear door trim panel. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install rear door trim panel 4. Connect battery negative cable. Subwoofer - Regular Cab REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6603 1. Disconnect and isolate the battery negative cable. 2. Remove mounting fasteners to subwoofer housing. 3. Disconnect electrical harness connector. 4. Remove subwoofer from vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6604 INSTALLATION 1. Position subwoofer housing into the vehicle. 2. Connect electrical harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 6605 3. Install mounting fasteners. 4. Connect battery negative cable. Subwoofer - Quad Cab REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise left rear seat to access subwoofer. 3. Disconnect electrical harness connector. 4. Remove mounting fasteners and remove subwoofer. INSTALLATION 1. Position subwoofer to vehicle. 2. Connect electrical harness connector. 3. Install and tighten mounting fasteners. 4. Lower seat. 5. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation Alarm Module: Description and Operation The Sentry Key Immobilizer Module (SKIM) (1) is the primary component of the Sentry Key Immobilizer System (SKIS). This module contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKIM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKIM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKIM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. The Sentry Key Immobilizer Module (SKIM) transmits Radio Frequency (RF) signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM) for gasoline engines or the Engine Control Module (ECM) for diesel engines, the ElectroMechanical Instrument Cluster (EMIC) and/or a diagnostic scan tool. The SKIM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKIM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM or ECM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the transponder in the ignition key. The SKIM then listens for a return RF signal from the transponder. If the SKIM receives an RF signal with a valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM/ECM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM or ECM is an invalid key. Therefore, if no message is received from the SKIM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6610 The SKIM also sends electronic messages to the EMIC which control the VTSS indicator. The SKIM sends messages to the EMIC to turn the indicator on for about three seconds when the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the indicator off for a duration of about one second. Then the SKIM sends messages to turn the indicator on or off based upon the results of the SKIS self-tests. If the VTSS indicator comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the On position, it sends messages to flash the VTSS indicator. The SKIM can also send messages to flash the indicator and to generate a single audible chime whenever the Customer Learn programming mode is being utilized. The SKIS will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. For diagnosis or initialization of the SKIM and the PCM/ECM, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6611 Alarm Module: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6612 8. Disconnect the wire harness connector (2) from the Sentry Key Immobilizer Module (SKIM) (1). 9. Remove the screw (3) that secures the SKIM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKIM. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6613 1. Position the Sentry Key Immobilizer Module (SKIM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKIM to the steering column housing. Tighten the screw to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the SKIM (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 6614 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.) 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.) 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 10. Reconnect the battery negative cable. NOTE: If the SKIM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6618 Module-Sentry Key Immobilizer (SKIM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6619 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6620 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6621 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Right Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 6625 Voice Activation Module: Diagrams Module-Hands Free C1 Module-Hands Free C2 Module-Hands Free C3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 6626 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation RELAY PACK DESCRIPTION Relay Pack Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. OPERATION In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay Winch Relay: Service and Repair Winch Relay RELAY REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6632 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6633 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). 3. Tighten the nuts to 3 N.m (25 in.lbs.) 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 N.m (85 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6634 6. Install the relay pack (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6635 Winch Relay: Service and Repair Winch Relay Pack RELAY PACK REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6636 3. Remove the nut and disconnect the red battery positive cable (1). NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6637 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 N.m (25 in.lbs.). 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 N.m (85 in.lbs.). 5. Install the relay pack cover (1) and install the three screws (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6638 6. Install the winch assembly (2). 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 6643 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 6644 Starter-Adjustable Pedals (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 6645 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6649 Remote Switch: Diagrams Switch-Remote Radio-Left Switch-Remote Radio-Right Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6650 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6651 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control MUX circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control MUX circuit to the Integrated Power Module (IPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6652 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK ASSEMBLY REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Page 6657 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 N.m (50 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 8w-54-3 (Except Connection Box) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 8w-54-4 (Except Add On Trailer Tow) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 8w-54-5 (Add On Trailer Tow) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 8w-54-6 (Add On Trailer Tow) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 6687 Trailer Connector: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 6688 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 N.m (17 in.lbs.) 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 6692 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft.lbs.). 3. Connect all wire harness support push pins. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 6693 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft.lbs.). 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Connector Views Trailer Lamps: Connector Views Wiring-Trailer Tow 4-Way Wiring-Trailer Tow 7-Way Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring Trailer Lamps: Description and Operation Trailer Tow Wiring In addition to the trailer tow wiring provisions, all vehicles include right and left trailer tow stop/turn relays installed in the PDC. When the FCM receives the appropriate inputs for normal turn signal, hazard warning or brake lamp operation, it responds by also energizing or de-energizing these trailer tow relays. When a trailer tow relay is energized, it provides battery voltage from a fused B(+) fuse to the trailer lamps through the trailer tow wiring to synchronize the illumination and flash rate of the trailer brake and turn signal lamps with those of the tow vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring > Page 6700 Trailer Lamps: Description and Operation Wiring-Trailer Tow The rear body wire harness on the rear frame (1) of all vehicles is equipped with a take out with a standard, light-duty 4-pin trailer tow connector (2) that is secured to the top of the trailer hitch platform (4) behind the rear bumper. Vehicles equipped with an optional factory-installed trailer towing package have a second take out with a connector (3) that plugs into a receptacle in the back of a heavy duty, sealed, 7-pin trailer tow connector that is located near the center of the rear bumper. Vehicles equipped with the trailer tow package also include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (1) that are stored in the glove box (2) when the vehicle is shipped from the factory. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The standard 4-pin trailer tow connector contains the following vehicle circuits: park/tail lamps, left stop/turn lamp, right stop/turn lamp, and ground. The optional trailer towing package 7-way connector contains the same circuits as the 4-pin connector plus the following additional circuits: backup lamp, trailer battery and electric brake. If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the truck battery while the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the vehicle glove box for Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring > Page 6701 type, location, and ampere rating of the fuse or circuit breaker. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 8w-54-3 (Except Connection Box) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 8w-54-4 (Except Add On Trailer Tow) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 8w-54-5 (Add On Trailer Tow) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 8w-54-6 (Add On Trailer Tow) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 6734 Trailer Connector: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 6735 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 N.m (17 in.lbs.) 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Right Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 6740 Voice Activation Module: Diagrams Module-Hands Free C1 Module-Hands Free C2 Module-Hands Free C3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 6741 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Cable > Component Information > Service and Repair Winch Cable: Service and Repair WIRE ROPE REMOVAL 1. Move the clutch lever (2) to "Free Spool" and disengage the wire rope. Pull out a portion to give it some slack. 2. Remove the clip (2), pin (1) and remove the hook (5) from the wire rope (4). 3. Pull the wire rope out and unwind the winch drum (1). 4. Remove the bolt (2) and remove the rope (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Cable > Component Information > Service and Repair > Page 6746 WARNING: Always keep hands and clothing clear of the wire rope, hook and fairlead opening during operation and when spooling. Failure to follow these instructions may result in personal injury or death. CAUTION: Wire rope must spool on the winch drum in the direction indicated. 1. Feed the new wire rope end (3) through the guide rollers. 2. Attach the flat side of the wire rope end (3) to the winch drum (1), apply red thread locker to the threads and install the bolt (2). 3. Wrap the wire rope around the spool approximately one time, in the direction indicated on the spool. 4. Tighten the bolt to 3 N.m (25 in.lbs.). 5. Arrange the wire rope so it will not kink or tangle when spooled. 6. Lock the winch drum by rotating the clutch lever (2) on the winch to "Engage." NOTE: Always make sure the clutch is engaged or disengaged fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Cable > Component Information > Service and Repair > Page 6747 7. Connect the remote control to the socket. 8. Install the hook (5), the pin (1) and clip (2) to the end of the wire rope (4). 9. Keep the rope under light tension and spool the rope back onto the winch drum in even layers. 10. Stop frequently to tighten and straighten the layers as necessary. 11. Repeat this process until the winch hook (5) is the same distance from the winch as the full length of the remote control. 12. Using the hook strap, walk the wire rope towards the guide rollers, carefully spooling in the remaining wire rope by pulsing the remote control switch. NOTE: If you do not have the hook strap, use a length of cord or similar when handling the hook during servicing of the winch. 13. Store the winch hook on the most outboard loop of the tow hook and remove the slack from the wire rope. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Description and Operation Winch Motor: Description and Operation MOTOR DESCRIPTION Motor The winch is driven on one end by a two direction electric motor powered by the vehicle electrical system. The motor is internally protected by a thermal switch that is activated when the motor gets too hot to operate efficiently. Winch motor controls consist of a relay pack mounted to the motor, and a remote control connected to the relay pack with a cord. The winch power source cables are connected to the relay pack which in turn feeds power to the winch motor through electrical cable connections. The main function of the relay pack is to allow the operator to switch the winch on and off in both directions. The winch relay pack also includes a Low Voltage Interrupt (LVI) used to prevent winch operation in the event of battery power dropping below 10 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Winch Motor Winch Motor: Service and Repair Winch Motor MOTOR REMOVAL 1. Remove the winch assembly (2). 2. Separate one of the roller shaft clips (1), remove the shaft (3) and the roller (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Winch Motor > Page 6753 3. Remove the bolts (3) and separate the support bracket (1) from the winch assembly (2). 4. Remove the relay pack (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Winch Motor > Page 6754 5. Stand winch assembly on the clutch end with the motor up to make it easier to align the motor coupler and drive shaft. 6. Remove the two motor mounting bolts (1) and carefully lift the motor (2) off of the drum assembly. INSTALLATION 1. With the winch assembly (1) standing on the clutch side verify that the motor coupler (2) is centered in the drive shaft opening (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Winch Motor > Page 6755 2. Position the motor drive shaft into the motor coupler splines and install the motor (2). 3. Install the bolts (1) and tighten to 9 N.m (82 in.lbs.). 4. Install the relay pack (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Winch Motor > Page 6756 5. Install the support bracket (1) and install the bolts (3). 6. Tighten the bolts to 108 N.m (80 ft.lbs.). 7. Position the wire rope through the roller opening and install the roller (4), shaft (3) and clip (1). 8. Install the winch assembly (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Winch Motor > Page 6757 Winch Motor: Service and Repair Winch Motor - Tie Rods MOTOR-TIE RODS REMOVAL 1. Remove the winch assembly. 2. Remove the bolts and remove the damaged tie rod(s). INSTALLATION 1. Install the tie rod(s) and install the bolts. 2. Tighten the bolts to 23 N.m (17 ft.lbs.). 3. Install the winch assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation RELAY PACK DESCRIPTION Relay Pack Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. OPERATION In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay Winch Relay: Service and Repair Winch Relay RELAY REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6763 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6764 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). 3. Tighten the nuts to 3 N.m (25 in.lbs.) 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 N.m (85 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6765 6. Install the relay pack (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6766 Winch Relay: Service and Repair Winch Relay Pack RELAY PACK REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6767 3. Remove the nut and disconnect the red battery positive cable (1). NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6768 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 N.m (25 in.lbs.). 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 N.m (85 in.lbs.). 5. Install the relay pack cover (1) and install the three screws (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 6769 6. Install the winch assembly (2). 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair Winch Roller / Cable Guide: Service and Repair WIRE ROPE GUIDE ROLLERS REMOVAL 1. Move the clutch lever (2) to "Free Spool" and disengage the wire rope. Pull out a portion to give it some slack. 2. Remove the clips (1). 3. Remove the roller axle rods (3) and remove the rollers (4) from the support bracket (2). 4. Separate the bushings (1) from the rollers (2) and replace if necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Page 6773 5. Remove the clips (3). 6. Remove the roller axle rods (2) and remove the rollers (4) from the support bracket (1). 7. Separate the bushings (2) from the rollers (1) and replace if necessary. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Page 6774 1. Install the roller bushings (2) onto the rollers (1). 2. Install the rollers (4) and install the axle rods (2). 3. Install the clips (3). 4. Install the roller bushings (1) onto the rollers (2). 5. Install the roller axle rods (3) and install the rollers (4) onto the support bracket (2). 6. Install the clips (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Page 6775 7. Store the winch hook on the most outboard loop of the tow hook. 8. Engage the clutch lever (2) and remove the slack from the wire rope. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation Body Control Module: Description and Operation The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6783 Body Control Module: Symptom Related Diagnostic Procedures Air Bag System AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems Diagnostic Test 1. AIRBAG WARNING INDICATOR ON WITHOUT ACTIVE TROUBLE CODES NOTE: Ensure the battery is fully charged. Turn the ignition on. Make sure that all active DTC's have been repaired before performing this procedure. With the DRBIII(R) read the WARNING LAMP STATES. Q: With no active DTCs, Does the LAMP REQ by ACM monitor show ON? YES: Go To 2 NO: Perform ORC VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test 2. REPLACE THE ORC WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER (ORC) IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. NOTE: When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected. Repair Replace the ORC. Perform ORC VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Occupant Restraint Controller (ORC) Verification Test NOTE: When reconnecting Airbag system components, the ignition must be turned off and the battery must be disconnected. Audio System Audio System Diagnosis Table Part 1 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6784 Audio System Diagnosis Table Part 2 Of 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6785 Audio System Diagnosis Table Part 3 Of 3 Any diagnosis of the Audio system should begin with the use of a scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Chime Inoperative CHIME INOPERATIVE POSSIBLE CAUSES - Cluster Diagnostic Test 1. ACTUATE THE CHIME WITH THE DRBIII Turn the ignition on. Close the doors. With the DRBIII(R) select: Electro/Mech Cluster and actuate the Chime. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6786 Q: Does the chime sound when actuated by the DRBIII(R)? YES: If the chime operates as it should, check for other reasons that the chime is being inoperative. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Sounds With Drivers Door Open and Key Removed From Ignition CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6787 Chime Sounds With Driver Door Open Key Removed POSSIBLE CAUSES - Key-in IGN SW status - Ignition switch shorted - (G26) Key-in ignition sw sense short to ground - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6788 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: Ensure the exterior lamps turn on and off properly and are off before continuing this test. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Remove the key from the ignition switch. Q: Does the DRBIII(R) show Key-In IGN OPEN? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. KEY-IN IGN SWITCH SHORTED Disconnect the Ignition Switch connector. Q: Did the chime turn off? YES: Check the Ignition Lock Cylinder for damage. If OK replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6789 3. (G26) KEY-IN IGNITION SWITCH SENSE WIRE SHORT TO GROUND Turn ignition off. Disconnect the Ignition Switch connector. Disconnect the Cluster C3 connector. Measure the resistance of the (G26) Key-in Ignition Switch Sense circuit to ground at the Ignition Switch connector. Q: Is the resistance below 100.0 ohms? YES: Repair the (G26) Key-In Ignition Switch Sense wire for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Warning System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6790 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6791 WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired chime warning system inputs to the ElectroMechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and methods. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Programmable Communications Interface (PCI) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Key In Ignition and Drivers Door Open Chime Inoperative KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6792 Key In Ignition And Driver's Door Open Chime Inoperative POSSIBLE CAUSES - (Z42) Ground open - (G26) Key-in ignition switch open - Ignition switch - Cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6793 Diagnostic Test 1. READ KEY-IN IGNITION SWITCH STATUS ON DRBIII NOTE: The driver's door ajar switch must be operational for the result of this test to be valid. Ensure that the Key is still in the Ignition Switch. With the DRBIII(R) select: Electro/Mech Cluster, Input Output. Read the Key-In IGN SW. Q: Does the DRBIII(R) show Key-In IGN CLOSED? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. IGNITION SWITCH GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch connector. Turn all lights off. Measure the resistance between ground and the (Z42) Ground circuit in the ignition switch harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6794 NO: Repair the (Z42) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. IGNITION SWITCH OPEN Connect the ignition switch connector if disconnected. Turn ignition on. With the ignition switch connector connected, back jumper the (G26) Key-In Ignition Switch Sense circuit to ground at the ignition switch connector. With the DRBIII(R), enter Instrument Cluster Input/Outputs and observe the Key-In IGN SW status. Q: Does the DRBIII display Key-In IGN SW: Closed? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. KEY-IN IGNITION SWITCH SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch harness connector. Disconnect the Cluster C3 harness connector. Measure the resistance of the (G26) Key-In Ignition Switch Sense circuit between the ignition switch connector and the Instrument Cluster C3 connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6795 Q: Is the resistance below 5.0 ohms? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G26) Key-In Ignition Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Vehicle Speed Warning Chime Problem VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in cluster - Cluster Diagnostic Test 1. WITH THE DRBIII CHECK THE COUNTRY CODE SETTING NOTE: The high speed warning chime is for Gulf Coast Countries only. Turn the ignition on. With the DRBIII(R) in Miscellaneous check the Cluster country code setting. Q: Is the country code incorrect? YES: Program the correct country code. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Heater Control Illumination Inoperative A/C HEATER CONTROL ILLUMINATION INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6796 A/C Heater Control Illumination Inoperative POSSIBLE CAUSES - Faults present in the cluster (MIC) - (E16) Panel lamps driver circuit open - Bulb(s) - filament open (single-zone HVAC module only) - Cluster (MIC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6797 - A/C Heater control Diagnostic Test 1. CHECK FOR DTCs IN THE CLUSTER (MIC) Turn the ignition on. With the DRBIII(R), read Cluster DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. TEST (E16) PANEL LAMPS DRIVER CIRCUIT USING A TEST LIGHT Turn the Headlamp switch on. Rotate the Cargo Dome switch to the full brightness setting. CAUTION: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (E16) Panel Lamps Driver circuit in the A/C Heater Control C1 harness connector. Q: Does the test light illuminate brightly? YES: (Dual-Zone Systems) Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: (Single-Zone Systems) Go To 3 NO: Go To 4 3. INSPECT THE INOPERATIVE BULB(S) Turn the ignition off. Remove the inoperative bulb(s) from the A/C Heater Control. NOTE: If necessary, hold the bulb in front of a lamp to see the filament. Inspect the bulb(s). Q: Is each inoperative bulb Ok? YES: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the inoperative bulb(s). Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6798 Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. CHECK (E16) PANEL LAMPS DRIVER CIRCUIT FOR AN OPEN Disconnect the A/C Heater Control C1 harness connector. Disconnect the Cluster C1 harness connector. Measure the resistance of the (E16) Panel Lamps Driver circuit between the A/C Heater Control C1 harness connector and the Cluster C1 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (E16) Panel Lamps Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Flashing A/C STATUS INDICATOR FLASHING Theory of Operation Running the AC Cooldown test will cause the A/C status indicator to flash. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. When the A/C status indicator is flashing, it will not indicate A/C operating status. However, the A/C mode switch will continue to function normally. For vehicles equipped with EBL, when the A/C status indicator is flashing, the EBL status indicator will not function. However, the EBL mode switch will continue to function normally. POSSIBLE CAUSES - A/C Cooldown test failed 1. PERFORM THE A/C COOLDOWN TEST NOTE: The following are prerequisites of the Cooldown Test. Verify each of the following before running the test: - Verify that no Evaporator Temperature Sensor related DTCs are not active. If active, diagnose and repair the DTC before proceeding. - Verify that the refrigerant system has an adequate charge. Check and repair as necessary before proceeding. - Verify that the blower motor operates correctly in all speeds. Diagnose and repair all blower related faults before proceeding. - Verify that the work area ambient temperature is above 21.1° C (70° F) before proceeding. Move the vehicle to a warmer work area if necessary. - Verify that the evaporator temperature is above 12.7° C (55° F) before proceeding. - Verify that the Mode Select control is set to the panel position. - Verify that the A/C compressor is not running. If the compressor is running, turn the A/C off and allow the evaporator to warm up before proceeding. Start the engine. Turn the Blower control to the high speed position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6799 With the DRBIII(R) in HVAC, select System Tests and then select AC Cooldown test. Allow one minute for the test to complete. One or more status messages will display on the DRBIII(R) after running the AC Cooldown Test. These messages will clear after paging back out of this test function. Therefore, it is important to note all messages before doing so. Q: Does the DRBIII(R) display a status message that indicates a fault has occurred? Yes, Blower Not On High Diagnose and repair the fault. Refer to Blower Not On High for the diagnostic test procedure. Yes, Cooldown Test Sensor Failure Diagnose and repair the fault. Refer to Cooldown Test Sensor Failure for the diagnostic test procedure. Yes, Cooldown Time Excessive Fault Diagnose and repair the fault. Refer to Cooldown Time Excessive Fault for the diagnostic test procedure. Yes, Cooldown Test Too Cold To Start Diagnose and repair the fault. Refer to Cooldown Test Too Cold To Start for the diagnostic test procedure. NO: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW A/C STATUS INDICATOR WILL NOT ILLUMINATE - A/C HEATER CONTROL WITHOUT EBL SW Theory of Operation Failing recalibration will prevent the A/C status indicator from operating but still allows the A/C mode switch to function normally. This test verifies if the status indicator is inoperable due to either a recalibration failure or a fault with the status indicator. POSSIBLE CAUSES - HVAC door recalibration failed - A/C Heater control Diagnostic Test 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Failed? YES: Diagnose and repair the fault(s). NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Dual-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6800 Actuator Circuit Test Diagnostics (Dual-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6801 messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test fault message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6802 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6803 5. RUN THE ACTUATOR CIRCUIT TEST Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6804 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6805 YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6806 Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Measure the resistance between the (C29) Mode Door 2 Driver circuit and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C33) Passenger Blend Door Driver circuit for a short to the (C29) Mode Door 2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 12 12. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, THE (C29) MODE DOOR 2 DRIVER CIRCUIT, & THE (C33) PASSENGER BLEND DOOR DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6807 Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, the (C29) Mode Door 2 Driver circuit, and the (C33) Passenger Blend Door Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 13 NO: Go To 14 13. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6808 14. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Actuator Circuit Test Diagnostics (Single-Zone) ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6809 Actuator Circuit Test Diagnostics (Single-Zone) Theory of Operation By running the Actuator Circuit Test, the A/C Heater Control can identify up to three door driver circuits shorted simultaneously. A Short Too Complex fault will set if more than three door driver circuits are shorted in the same direction (e.g. four door driver circuits all shorted to ground) or if two or more door driver circuits are shorted with at least one door driver circuit shorted to ignition and one door driver circuit shorted to ground. Fault messages displaying XXX Driver/Circuit Shorted to Ignition/Battery and XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. Fault messages displaying the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6810 shorted together. To ensure a proper diagnosis, repair all Short Too Complex fault messages first, all common door driver circuit related fault messages second, and all other fault messages last. In addition, always test the door driver circuits after each repair by cycling the ignition switch and then running the Actuator Circuit Test again to ensure that no new faults exits. Diagnostic Test 1. SELECT THE CORRECT PROCEDURE STEPS TO DIAGNOSE THE ACTUATOR CIRCUIT TEST FAULT(S) Q: Which Actuator Circuit Test message is present? XXX Driver/Circuit Shorted to Ground Go To 2 XXX Driver/Circuit Shorted to Ignition or Battery Go To 4 Short Too Complex Go To 6 XXX Driver/Circuit Shorted to Ground & to Ignition or Battery Go To 8 2. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance of the applicable door driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the door driver circuit for a short to ground. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE RESISTANCE BETWEEN THE (C34) COMMON DOOR DRIVER CIRCUIT & THE DOOR DRIVER CIRCUIT TESTED IN THE PREVIOUS STEP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6811 Measure the resistance between the (C34) Common Door Driver circuit and the applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms? YES: Replace the door actuator. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 4. CHECK THE DOOR DRIVER CIRCUIT IDENTIFIED IN THE ACTUATOR CIRCUIT TEST MESSAGE FORA SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the applicable door driver circuit. Q: Is there any voltage present? YES: Repair the door driver circuit for a short to voltage. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6812 5. RUN THE ACTUATOR CIRCUIT TEST Turn the ignition off. Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Step 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Turn the ignition on. Measure the voltage of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit. Q: Is there any voltage present on any of the circuits? YES: Repair all door driver circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT, THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6813 Turn the ignition off. Measure the resistance of the (C34) Common Door Driver Circuit, the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit between ground and the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all door driver circuits with a resistance below 10k ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Turn the ignition off. Disconnect the A/C Heater Control C1 harness connector. Measure the resistance between the (C32) Recirculation Door Driver circuit and the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C32) Recirculation Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6814 NO: Go To 9 9. CHECK THE (C61) BLEND DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C801) MODE DOOR 1 DRIVER CIRCUIT & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C61) Blend Door Driver circuit and the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C61) Blend Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (C801) MODE DOOR 1 DRIVER CIRCUIT FOR A SHORT TO THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C801) Mode Door 1 Driver circuit and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms? YES: Repair the (C29) Mode Door 2 Driver circuit for a short to the (C801) Mode Door 1 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6815 Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 11. CHECK THE (C34) COMMON DOOR DRIVER CIRCUIT FOR A SHORT TO THE (C32) RECIRCULATION DOOR DRIVER CIRCUIT, THE (C61) BLEND DOOR DRIVER CIRCUIT, THE (C801) MODE DOOR 1 DRIVER CIRCUIT, & THE (C29) MODE DOOR 2 DRIVER CIRCUIT Measure the resistance between the (C34) Common Door Driver Circuit and the (C32) Recirculation Door Driver circuit, the (C61) Blend Door Driver circuit, the (C801) Mode Door 1 Driver circuit, and the (C29) Mode Door 2 Driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 30.0 ohms on any of the circuits? YES: Go To 12 NO: Go To 13 12. CHECK THE DOOR DRIVER CIRCUITS WHOSE RESISTANCE WAS BELOW 30.0 OHMS IN THE PREVIOUS STEP FOR A SHORT TO THE (C34) COMMON DOOR DRIVER CIRCUIT Disconnect all door actuator harness connectors whose circuit resistance was below 30.0 ohms. Measure the resistance between the (C34) Common Door Driver circuit and each applicable door driver circuit in the A/C Heater Control C1 harness connector. Q: Is the resistance below 10k ohms on any of the circuits? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6816 YES: Repair the door driver circuits with a resistance below 10k ohms for a short to the (C34) Common Door Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace all door actuators with a resistance below 30.0 ohms. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 13. RUN THE ACTUATOR CIRCUIT TEST Reconnect the A/C Heater Control C1 harness connector. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: What message does the DRBIII(R) display? Same message as from start of test Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Different message than from start of test Using the wiring diagram as a guide, inspect the wiring and connectors for conditions causing an intermittent short that set the original test message. Repair as necessary. If the DRBIII(R) displays a message for a different door driver circuit, return to Test 1 of this diagnostic procedure. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Dual-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (DUAL-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6817 Blend/Mode/Recirc Door Operation Improper (Dual-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6818 - Door(s) bound up, warped, worn, damaged - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (DUAL-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Passenger Blend Door Function Test Go To 6 Driver Blend Door Function Test Go To 7 Recirculation Door Function Test Go To 8 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6819 Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK PASSENGER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Passenger Blend control to the full hot position. Move the Passenger Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the passenger's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Passenger Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK DRIVER BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Driver Blend control to the full hot position. Move the Driver Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the driver's panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Driver Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blend/Mode/Recirc Door Operation Improper - Single-Zone BLEND/MODE/RECIRC DOOR OPERATION IMPROPER (SINGLE-ZONE) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6820 Blend/Mode/Recirc Door Operation Improper (Single-Zone) POSSIBLE CAUSES - Door driver circuit(s) shorted to ground - Door driver circuit(s) shorted to voltage - Door driver circuit shorted to other door driver circuit(s) - Door driver circuit(s) open - Door(s) bound up, warped, worn, damaged Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6821 - Door linkage(s) excessively worn, disconnected, missing, broken - Door actuator(s) broken Diagnostic Test 1. RUN THE ACTUATOR CIRCUIT TEST NOTE: Diagnose and repair all Actuator Circuit Test faults before diagnosing Calibration faults. Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select Actuator Circuit Test. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any Actuator Circuit Test fault messages? YES: Diagnose and repair the fault(s). Refer to *ACTUATOR CIRCUIT TEST DIAGNOSTICS (SINGLE-ZONE) for the diagnostic test procedure. NO: Go To 2 2. CHECK FOR DTCS IN THE A/C HEATER CONTROL NOTE: Diagnose and repair all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R), read HVAC DTCs. Q: Does the DRBIII(R) display any DTCs? YES: Diagnose and repair the DTC(s). NO: Go To 3 3. RUN THE HVAC DOOR RECALIBRATION TEST NOTE: Diagnose and repair all Actuator Circuit Test faults and all Overcurrent DTCs before diagnosing Calibration faults. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display any HVAC Door Recalibration fault messages? YES: Diagnose and repair the fault(s). NO: Go To 4 4. SELECT THE APPLICABLE TEST TO DIAGNOSE THE DOOR WITH THE REPORTED FAULT Select the applicable test to diagnose the door with the reported fault Mode Door Function Test Go To 5 Blend Door Function Test Go To 6 Recirculation Door Function Test Go To 7 5. CHECK MODE DOOR 1 & MODE DOOR 2 FUNCTION Start the engine. Turn the Blower control to the high speed position. NOTE: - The Mode Door 1 must be at its physical end of travel in the panel position to correctly direct airflow to the Mode Door 2. - The Mode Door 2 must be at its physical end of travel in the floor-defrost position to correctly direct airflow to the Mode Door 1. Turn the Mode Select control to each door position for a minimum of 30 seconds and check for airflow from the corresponding vents. Q: Does air flow from the correct vents for each door position? Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6822 YES: Test Complete. NO: Remove the Mode Door Actuator 1 and the Mode Door Actuator 2 from the A/C-Heater Housing Assembly. By hand, one door actuator at a time, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and bound up, warped, worn, and damaged doors. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. CHECK BLEND DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Turn the Mode Select control to the panel position. Move the Blend control to the full hot position. Move the Blend control to the full cold position, in 25% increments, while checking for a change in airflow air temperature coming from the panel vents. Q: Does the airflow air temperature change with respect to the position of the blend control? YES: Test Complete. NO: Remove Blend Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK RECIRCULATION DOOR FUNCTION Start the engine. Turn the Blower control to the high speed position. Press the MAX control off (LED not Illuminated). Press the MAX control on (LED Illuminated). The sound of the air flowing through the ducts should get louder as the recirculation door opens to bring in recirculated air. Q: Does the sound of the airflow get louder after pressing the MAX control on? YES: Test Complete. NO: Remove Recirculation Door Actuator from A/C-Heater Housing Assembly. By hand, attempt to rotate the door actuator in both directions. Also, inspect for disconnected, missing, or broken door actuator linkage, and a bound up, warped, worn, and damaged door. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Blower Motor Inoperative (Except SRT10) BLOWER MOTOR INOPERATIVE (EXCEPT SRT10) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6823 Blower Motor Inoperative (Except SRT10) POSSIBLE CAUSES - (C7) Blower motor feed circuit shorted to ground - (A970) Fused B(+) circuit shorted to ground - (C70) Blower motor high driver circuit open - (Z134) Ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6824 - (C7) Blower motor feed circuit open - (A970) Fused B(+) circuit open - IPM fuse #4 open - Blower motor - Ignition switch - A/C heater control Diagnostic Test 1. CHECK THE FUSE Turn the ignition off. Remove and inspect IPM Fuse #4. Q: Is the fuse open? YES: Replace IPM Fuse #4 and Go To 2. NO: Reinstall IPM Fuse #4 and Go To 5. 2. CHECK BLOWER MOTOR OPERATION Turn the ignition on. Turn the blower on and operate it in all speeds and modes. Q: Does the blower motor operate properly without blowing the fuse? YES: Check the (C7) Blower Motor Feed circuit and the (A970) Fused B(+) circuit for an intermittent short to ground. Repair as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6825 Turn the ignition off. Disconnect the Blower Motor harness connector. Measure the resistance of the (C7) Blower Motor Feed circuit between ground and the Blower Motor harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C7) Blower Motor Feed circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (A970) FUSED B(+) CIRCUIT FOR A SHORT TO GROUND Disconnect the Ignition Switch harness connector. Measure the resistance of the (A970) Fused B(+) circuit between ground and the Ignition Switch harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (A970) Fused B(+) circuit for a short to ground and replace the fuse. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor and fuse. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6826 Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Blower Motor harness connector. Q: Does the test light illuminate brightly? YES: Go To 6 NO: Go To 9 6. CHECK BLOWER MOTOR OPERATION BY BYPASSING THE A/C HEATER CONTROL Turn the ignition off. Connect a jumper wire between ground and the (C70) Blower Motor High Driver circuit in the Blower Motor harness connector. Turn the ignition on. Q: Does the blower motor run at high speed? YES: Go To 7 NO: Replace the Blower Motor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 7. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6827 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor harness connector. Measure the resistance of the (C70) Blower Motor High Driver circuit between the A/C Heater Control C2 harness connector and the Blower Motor harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 8 NO: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (Z134) GROUND CIRCUIT FOR AN OPEN Measure the resistance of the (Z134) Ground circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Replace the A/C Heater Control. NO: Repair the (Z134) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C7) BLOWER MOTOR FEED CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6828 NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C7) Blower Motor Feed circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Repair the (C7) Blower Motor Feed circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 10 10. CHECK THE (A970) FUSED B(+) CIRCUIT FOR AN OPEN NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (A970) Fused B(+) circuit in the Ignition Switch harness connector. Q: Does the test light illuminate brightly? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (A970) Fused B(+) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6829 Blower Speed Does Not Correspond With Control Setting BLOWER SPEED DOES NOT CORRESPOND WITH CONTROL SETTING Blower Speed Does Not Correspond With Control Setting POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6830 - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to ground - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted to voltage - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit shorted together - (C71) Blower motor low driver circuit/(C73) blower motor M2 driver circuit/(C72) blower motor M1 driver circuit/(C70) blower motor high driver circuit open - Blower motor resistor block open - A/C heater control Diagnostic Test 1. CHECK IF THE BLOWER MOTOR RUNS WITH THE BLOWER CONTROL IN THE OFF POSITION Turn the Blower control to the Off position. Turn the ignition on. Q: Does the blower motor run? YES: Go To 2 NO: Go To 3 2. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit between ground and the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms on any of the circuits? YES: Repair all circuits with a resistance below 10K ohms for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT USING A TEST LIGHT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6831 Turn the ignition off. Disconnect the A/C Heater Control C2 harness connector. Turn the ignition on. NOTE: The test light must illuminate brightly. Compare the brightness to that of a direct connection to the battery. Using a 12-volt test light connected to ground, back probe the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Does the test light illuminate brightly on each circuit? YES: Go To 4 NO: Go To 8 4. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT, THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the voltage of the (C71) Blower Motor Low Driver circuit, the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is there voltage present on any of the circuits? YES: Repair all circuits with voltage present for a short to voltage. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6832 NO: GO TO 5 5. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR A SHORT TO THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT, THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT, & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C71) Blower Motor Low Driver circuit and the (C73) Blower Motor M2 Driver circuit, the (C72) Blower Motor M1 Driver circuit, and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C71) Blower Motor Low Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C71) Blower Motor Low Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR A SHORT TO THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT & THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Measure the resistance between the (C73) Blower Motor M2 Driver circuit and the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms between the (C73) Blower Motor M2 Driver circuit and any of the other circuits? YES: Repair all circuits with a resistance below 10k ohms for a short to the (C73) Blower Motor M2 Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR A SHORT TO THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6833 Measure the resistance between the (C72) Blower Motor M1 Driver circuit and the (C70) Blower Motor High Driver circuit in the A/C Heater Control C2 harness connector. Q: Is the resistance below 10K ohms? YES: Repair the (C72) Blower Motor M1 Driver circuit for a short to the (C70) Blower Motor High Driver circuit. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the A/C Heater Control. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 8. CHECK THE (C71) BLOWER MOTOR LOW DRIVER CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Blower Motor Resistor Block harness connector. Measure the resistance of the (C71) Blower Motor Low Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 9 NO: Repair the (C71) Blower Motor Low Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 9. CHECK THE (C73) BLOWER MOTOR M2 DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6834 Measure the resistance of the (C73) Blower Motor M2 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 10 NO: Repair the (C73) Blower Motor M2 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. CHECK THE (C72) BLOWER MOTOR M1 DRIVER CIRCUIT FOR AN OPEN Measure the resistance of the (C72) Blower Motor M1 Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 11 NO: Repair the (C72) Blower Motor M1 Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 11. CHECK THE (C70) BLOWER MOTOR HIGH DRIVER CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6835 Measure the resistance of the (C70) Blower Motor High Driver circuit between the Blower Motor Resistor Block harness connector and the A/C Heater Control C2 harness connector. Q: Is the resistance below 5.0 ohms? YES: Repair the (C70) Blower Motor High Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Blower Motor Resistor Block. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test EBL Status Indicator Flashing EBL STATUS INDICATOR FLASHING Theory of Operation Running the HVAC Door Recalibration will cause the EBL status indicator to flash. If recalibration fails, the status indicator will continue to flash until either the system passes recalibration or the ignition key is cycled. When the EBL status indicator is flashing, it will not indicate EBL operating status. However, the EBL mode switch will continue to function normally. When the EBL status indicator is flashing, the A/C status indicator will not function. However, the A/C mode switch will continue to function normally. POSSIBLE CAUSES - HVAC door recalibration failed 1. PERFORM THE HVAC DOOR RECALIBRATION Turn the ignition on. With the DRBIII(R) in HVAC, select System Tests and then select HVAC Door Recalibration. Allow the test to run to completion before proceeding. Q: Does the DRBIII(R) display: Recalibration Test Passed? YES: Test Complete. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Diagnose and repair the fault(s). Horn HORNS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6836 Horns Inoperative POSSIBLE CAUSES - DTC present - Fuse #45 - Horns - Horn ground circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6837 - Horn relay output circuit open - Horn switch - Horn switch ground - Clockspring - Horn switch sense open - Integrated power module - Instrument cluster - Front control module Diagnostic Test 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to symptom list. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. ACTUATE HORN RELAY With the DRBIII(R), actuate the Horn Relay. Q: Do the horns operate? YES: Go To 3 NO: Go To 7 3. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch. Measure the resistance of the Horn Switch ground circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the horn switch ground as necessary. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. HORN SWITCH WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. CAUTION: Do not place an intact undeployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. Gain access to the horn switch connector. WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the Horn switch connector and ground. Q: Did the horns sound? YES: Replace the horn switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CLOCKSPRING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6838 Turn the ignition off. Disconnect the clockspring C1 connector. Momentarily connect a jumper wire between the Horn Switch Sense circuit at the clockspring connector and ground. Q: Did the horns sound? YES: Replace the clockspring. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. HORN SWITCH SENSE Turn the ignition off. Disconnect the clockspring C1 connector. Disconnect the Instrument Cluster C3 connector. NOTE: Check connectors - Clean/repair as necessary. Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Instrument Cluster C3 connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Horn Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6839 Tests/Body Verification Test 7. CHECK FUSE #45 Turn the ignition off. Using a 12-volt test light connected to ground, check the Horn fuse #45 in the IPM. Q: Is the fuse open? YES: Replace the fuse. Check for a short to ground in the Horn Relay Output circuit from the IPM to the horns. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. HORN RELAY OUTPUT Disconnect a horn connector. With the DRBIII(R), actuate the Horn Relay. Using a 12-volt test light connected to ground, check the Horn Relay Output circuit. Q: Does the test light illuminate brightly? YES: Go To 9 NO: Go To 10 9. HORN GROUND CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6840 Turn the ignition off. Disconnect the Horn connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit in the horn connector. Q: Does the test light illuminate brightly? YES: Replace the Horns. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 10. HORN RELAY OUTPUT CIRCUIT OPEN Gain access to the IPM C1 connector. Using a 12-volt test light connected to ground, back probe the Horn Relay Output circuit in the IPM C1 connector. Turn the ignition on. With the DRBIII(R), the actuate the horn relay. Q: Does the test light illuminate brightly? YES: Repair the Horn Relay Output circuit for an open. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 11 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6841 11. INTEGRATED POWER MODULE Turn the ignition off. Remove the Front Control Module from the Integrated Power Module. NOTE: - Check connectors - Clean/repair as necessary. - The test light is still connected to the C1 connector. Momentarily jumper the Horn Relay Control circuit to ground at the FCM connector. Q: Does the test light illuminate brightly? YES: Replace the Front Control Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Integrated Power Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test All Gauges Inoperative ALL GAUGES INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6842 All Gauges Inoperative POSSIBLE CAUSES - No response - PCI BUS - No response - PCI BUS - powertrain control module - PCI BUS - instrument cluster - (F21) Fused ignition switch output (run/start) circuit short to ground - (F1) Fused ignition switch output (off/run/start) circuit short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6843 - (F21) Fused ignition switch output (run/start) circuit open - (F1) Fused ignition switch output (off/run/start) circuit open - (Z18) Instrument cluster ground circuit for an open - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS NOTE: Diagnose and repair any MIC, PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test. Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), select Body, MIC, SYSTEM TESTS, PCM Monitor. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PCI BUS - INSTRUMENT CLUSTER Turn the ignition on. With the DRBIII(R), select Body, MIC, MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Inspect the #20 Fuse in the PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6844 If the fuse is open, replace with proper rated fuse. Turn the ignition on for one minute. Turn the ignition off. Inspect the #20 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F21) Fused Ignition Switch Output (Unlock/Run) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. If the fuse is open, replace with the proper rated fuse. Turn the ignition on for 1 minute. Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. Q: Is the fuse open? YES: Repair the (F1) Fused Ignition Switch Output (Run/Start) circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6845 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F1) Fused Ignition Switch Output (Off/Run/Start) circuit and ground. Q: Is the voltage below 10.5 volts? YES: Repair the (F1) Fused Ignition Switch Output (Off/Run/ Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 8 8. CHECK THE (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6846 Measure the resistance between ground and the (Z18) Instrument Cluster Ground circuit. Q: Is the resistance below 5.0 ohms? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z18) Instrument Cluster Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Any PCI Indicator Inoperative ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - Indicator message not received - Instrument cluster DIAGNOSTIC TEST 1. NO RESPONSE - PCI BUS Turn the ignition on. With the DRBIII(R), select System Monitors, then J1850 Module Scan. Q: Does the DRBIII(R) display MIC PRESENT on the BUS? YES: Go To 2 NO: Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. NO RESPONSE - INSTRUMENT CLUSTER With the DRBIII(R), select MIC, then MODULE DISPLAY. Q: Does the DRBIII(R) display NO RESPONSE from MIC? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE INSTRUMENT CLUSTER. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. NO RESPONSE - PCI BUS With the DRBIII(R), select Body, MIC, MONITORS, PCI BUS MONITORS. Q: Does the DRBIII(R) display PCM INACTIVE on the BUS? YES: Refer to the symptom list for problems related to NO RESPONSE FROM THE POWERTRAIN CONTROL MODULE. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. INDICATOR MESSAGE NOT RECEIVED NOTE: Diagnose and repair any PCM or BCM DTCs before proceeding with this test. Perform the Instrument Cluster Self Test. Depress and hold the Trip Odometer button while turning the ignition from the off to the on position. Observe the indicator in question. Q: Did the indicator illuminate? YES: Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6847 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Always On BRAKE WARNING INDICATOR ALWAYS ON Brake Warning Indicator Always On Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6848 POSSIBLE CAUSES - (B20) Brake fluid level sensor sense circuit short to ground - (B25) Park brake switch sense circuit short to ground - Brake fluid level sensor - Park brake switch - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. BRAKE FLUID LEVEL SENSOR NOTE: Diagnose and repair any MIC, Brake, or Communication DTCs before proceeding with this test. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance of the Brake Fluid Level Sensor between pin 1 and pin 2. Q: Does the resistance measure less than 900 ohms? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6849 Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance between ground and the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. PARK BRAKE SWITCH Turn the ignition off. Disconnect the Park Brake Switch harness connector. Turn the ignition on. Observe the Brake warning indicator. Q: Did the Brake warning indicator illuminate briefly and then turn off? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6850 4. (B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (B25) Park Brake Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 5. ANTI-LOCK BRAKES MODULE Turn the ignition off. Reconnect any harness connector(s) that were previously disconnected. Turn the ignition on. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Brake Warning Indicator Inoperative BRAKE WARNING INDICATOR INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6851 Brake Warning Indicator Inoperative POSSIBLE CAUSES - (Z420) Brake fluid level sensor ground circuit open - (B25) Park brake switch sense circuit open - (B20) Brake fluid level sense circuit open - Park brake switch - Brake fluid level sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6852 - Anti-lock brakes module - Instrument cluster DIAGNOSTIC TEST 1. FAULT LOCATION NOTE: Diagnose and repair any MIC, ABS, or Communication DTCs before proceeding with this test. Q: Is the Brake warning indicator only inoperative using the Park Brake? YES: Go To 2 NO: Go To 4 2. PARK BRAKE SWITCH Disconnect the Park Brake Switch harness connector. Connect a jumper wire between the (B25) Park Brake Switch Sense circuit and ground. Turn the ignition on. Observe the BRAKE indicator. Q: Did the BRAKE indicator illuminate? YES: Replace the Park Brake Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6853 Turn the ignition off. Disconnect the (B25) Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (B25) Park Brake Switch Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B25) Park Brake Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. BRAKE FLUID LEVEL SENSOR Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Q: Does the Brake warning indicator illuminate? YES: Replace the Brake Fluid Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6854 5. (Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance between ground and the (Z420) Brake Fluid Level Sensor Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z420) Brake Fluid Level Sensor Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. (B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance of the (B20) Brake Fluid Level Sensor Sense circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (B20) Brake Fluid Level Sensor Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6855 Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 7 7. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Anti-lock Brakes Module harness connector. Connect a jumper wire between the (B25) Brake Fluid Level Sensor Sense circuit and ground. With the DRBIII(R) in Inputs/Outputs, read the Brake Fluid Level Sensor state. Q: Does the DRBIII(R) display "Closed"? YES: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Anti-lock Brakes Module. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Fuel Gauge Inaccurate FUEL GAUGE INACCURATE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6856 Fuel Gauge Inaccurate POSSIBLE CAUSES - Fuel level sensor wiring - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6857 1. DTC PRESENT NOTE: Diagnose and repair any PCI Bus problems before proceeding with this test. Turn the ignition on. With the DRBIII(R), read the PCM DTCs. Q: Does the DRBIII(R) display any Fuel Level Sensor related DTC? YES: Refer to the Powertrain Diagnostic Information for the related symptom(s). Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test as follows: Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the Fuel Gauge during the Self Test. The Fuel Gauge pointer should pause at each of these following positions: E, 1/4, 1/2, 3/4, Full, and back to E. Q: Does the Fuel Gauge function as described above? YES: Go To 3 NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. FUEL LEVEL SENSOR WIRING Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Disconnect the PCM C2 and C3 harness connectors. Measure the resistance of the (N4) Fuel Level Sensor Signal circuit between the Fuel Pump Module harness connector and the PCM harness connector. Measure the resistance of the (K900) Sensor Ground circuit between the Fuel Pump Module harness connector and the PCM harness connector. Q: Is the resistance below 5.0 ohms on both circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6858 YES: Replace the Fuel Level Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the circuits with a resistance above 5.0 ohms for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Gauge Inoperative - Gas Engines ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module - Instrument cluster DIAGNOSTIC TEST 1. POWERTRAIN CONTROL MODULE Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any PCM DTCs? YES: Refer to the DRIVEABILITY category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Perform the Instrument Cluster Self Test. NOTE: The Self Test can be initiated manually by depressing and holding the Trip Reset button while turning the ignition on, or by using the DRBIII(R). Observe the gauge in question while the Instrument Cluster performs the Self Test. The gauges should position at the following calibrations points: Speedometer MPH: 0, 20, 60, 90 Tachometer Gas: 0, 1000, 3000, 6000 Fuel: E, 1/4, 1/2, 3/4, F Coolant: Cold, 1/4, 1/2, 3/4, HI Volts: 6, 9, 12, 15, 17 Q: Did the gauge in question operate properly? YES: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wire harness. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test PRNDL Not Displaying Correct Position (EATX Vehicles) PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster DIAGNOSTIC TEST 1. DTC PRESENT NOTE: - Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle. - Ensure that there is communication between the Cluster and PCM before proceeding with this test. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6859 - Diagnose and repair any DTCs before proceeding with this test. - Ensure that the PCM passes the Shift Lever Test with the DRBIII(R) before proceeding with this test. Turn the ignition on. With the DRBIII(R), read DTCs. Q: Does the DRBIII(R) display any MIC or PCM DTCs? YES: Refer to the correct symptom list for problems related to DTCs. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. INSTRUMENT CLUSTER Perform the Instrument Cluster Self Test. Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the PRNDL display during the Self Test. Q: Did any part of the VF display fail to illuminate? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: The condition is not present at this time. Monitor DRBIII(R) parameters while wiggling the related wiring harness, refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off SEAT BELT WARNING INDICATOR ALWAYS OFF Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6860 Seat Belt Warning Indicator Always Off POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster Diagnostic Art Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6861 1. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR A SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always Off - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6862 Seat Belt Warning Indicator Always Off - Standard Cab POSSIBLE CAUSES - (G10) Seat belt switch sense circuit short to ground - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6863 1. (G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt Switch Sense circuit. Q: Is the resistance below 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on SEAT BELT WARNING INDICATOR ALWAYS ON Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6864 Seat Belt Warning Indicator Always On POSSIBLE CAUSES - (Z951) Seat belt switch ground circuit for an open - (G10) Seat belt switch sense circuit open - Seat belt switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6865 DIAGNOSTIC TEST 1. CHECK THE OPERATION OF THE SEAT BELT SWITCH Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate for approximately 4 seconds and then turn off? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Measure the resistance between ground and the (Z951) Seat Belt Switch Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6866 3. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Seat Belt Warning Indicator Always on - Standard Cab SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6867 Seat Belt Warning Indicator Always On - Standard Cab POSSIBLE CAUSES - (F983) Fused ignition switch output (run-acc) circuit open - (Z951) Seat belt switch ground circuit open - (G10) Seat belt switch sense circuit open - Seat belt tensioner reducer Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6868 - Seat belt switch - Instrument cluster 1. (F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN Turn the ignition off. Disconnect the Seat Belt Tensioner Reducer harness connector. Turn the ignition on. Measure the voltage between the (F983) Fused Ignition Switch Output (Run-Acc) circuit and ground in the Tensioner Reducer harness connector. Q: Is the voltage above 10.5 volts? YES: Go To 2 NO: Repair the (F983) Fused Ignition Switch Output (Run-Acc) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 2. SEAT BELT TENSIONER REDUCER Ensure that the Seat Belt Tensioner Reducer harness connector is connected. Measure the voltage between the (G10) Seat Belt Switch Sense circuit and ground in the Seat Belt Tensioner Reducer harness connector (cavity 2). Q: Is there any voltage present? YES: Go To 3 NO: Replace the Seat Belt Tensioner Reducer. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. SEAT BELT SWITCH Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6869 Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator. Q: Did the Seat Belt Warning Indicator illuminate? YES: Replace the Seat Belt Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN Turn the ignition off. Measure the resistance between ground and the (Z951) Seat Belt Switch circuit. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (Z951) Seat Belt Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6870 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector. Q: Is the resistance above 5.0 ohms? YES: Repair the (G10) Seat Belt Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and configure the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Open DRIVER DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6871 Driver Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z75) driver door ajar switch ground circuit - Open (G75) driver door ajar switch sense circuit - Open driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6872 DIAGNOSTIC TEST 1. OPEN DRIVER DOOR AJAR SWITCH Disconnect the Driver Door Latch connector. Connect a jumper wire between the (G75) Sense circuit and the (Z75) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z75) DRIVER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z75) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES:Go To 3 NO: Repair the (Z75) Driver Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6873 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G75) Driver Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G75) Driver Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Ajar Circuit Shorted to Ground DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6874 Driver Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G75) Driver door ajar switch sense circuit short to ground - Driver door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6875 DIAGNOSTIC TEST 1. DRIVER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the DRV DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Driver Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Driver Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G75) DRIVER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G75) Driver Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G75) Driver Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6876 LEFT REAR DOOR AJAR CIRCUIT OPEN Left Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z79) left rear door ajar switch ground circuit - Open (G77) left rear door ajar switch sense circuit - Open left rear door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6877 - Instrument cluster DIAGNOSTIC TEST 1. OPEN LEFT REAR DOOR AJAR SWITCH Disconnect the Left Rear Door Latch connector. Connect a jumper wire between the (G77) Sense circuit and the Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO:Go To 2 2. OPEN (Z79) LEFT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z79) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z79) Left Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6878 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G77) Left Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Ajar Circuit Shorted to Ground LEFT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6879 Left Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G77) Left rear door ajar switch sense circuit short to ground - Left rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6880 DIAGNOSTIC TEST 1. LEFT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the L R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Left Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES:Replace the Left Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G77) LEFT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G77) Left Rear Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G77) Left Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6881 PASSENGER DOOR AJAR CIRCUIT OPEN Passenger Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z74) passenger door ajar switch ground circuit - Open (G74) passenger door ajar switch sense circuit - Open passenger door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6882 - Instrument cluster DIAGNOSTIC TEST 1. OPEN PASSENGER DOOR AJAR SWITCH Disconnect the Passenger Door Latch connector. Connect a jumper wire between the (G74) Sense circuit and the (Z74) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z74) PASSENGER DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z74) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z74) Passenger Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6883 Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G74) Passenger Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G74) Passenger Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Ajar Circuit Shorted to Ground PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6884 Passenger Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G74) Passenger door ajar switch sense circuit short to ground - Passenger door ajar switch - Instrument cluster DIAGNOSTIC TEST Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6885 1. PASSENGER DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the PASS DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Passenger Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Passenger Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G74) PASSENGER DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G74) Passenger Door Ajar Switch Sense circuit and test for a short to ground. Turn the ignition on. Q: Does the test light illuminate brightly? YES: Repair the (G74) Passenger Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Open RIGHT REAR DOOR AJAR CIRCUIT OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6886 Right Rear Door Ajar Circuit Open POSSIBLE CAUSES - Open (Z72) right rear door ajar switch ground circuit - Open (G76) right rear door ajar switch sense circuit - Open right rear door ajar switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6887 - Instrument cluster DIAGNOSTIC TEST 1. OPEN RIGHT REAR DOOR AJAR SWITCH Disconnect the Right Rear Door Latch connector. Connect a jumper wire between the (G76) Sense circuit and the (Z72) Ground circuit. With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. Q: Does the DRBIII(R) display CLOSED? YES: Replace the Right Rear Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. OPEN (Z72) RIGHT REAR DOOR AJAR SWITCH GROUND CIRCUIT Using a 12-volt Test Light connected to 12-volts, test the (Z72) Ground circuit in the Door Latch connector. Q: Does the test light illuminate brightly? YES: Go To 3 NO: Repair the (Z72) Right Rear Door Ajar Switch Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. OPEN (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6888 Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G76) Right Rear Door Ajar Switch Sense circuit between the Instrument Cluster connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Ajar Circuit Shorted to Ground RIGHT REAR DOOR AJAR CIRCUIT SHORTED TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6889 Right Rear Door Ajar Circuit Shorted To Ground POSSIBLE CAUSES - (G76) Right rear door ajar switch sense circuit short to ground - Right rear door ajar switch - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6890 DIAGNOSTIC TEST 1. RIGHT REAR DOOR AJAR SWITCH SHORT TO GROUND With the DRBIII(R) in Inputs/Outputs, read the R R DOOR AJAR SW state. While monitoring the DRBIII(R), disconnect the Right Rear Door Latch connector. Q: Did the Switch State change from CLOSED to OPEN? YES: Replace the Right Rear Door Ajar Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (G76) RIGHT REAR DOOR AJAR SWITCH SENSE CIRCUIT SHORT TO GROUND Disconnect the Instrument Cluster C3 harness connector. Using a 12-volt test light connected to 12-volts, probe the (G76) Right Rear Door Ajar Switch Sense circuit and test for a short to ground. Q: Does the test light illuminate brightly? YES: Repair the (G76) Right Rear Door Ajar Switch Sense circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Average Fuel Economy Inaccurate or Wrong AVERAGE FUEL ECONOMY INACCURATE OR WRONG Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6891 POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. CMTC or EVIC Inoperative CMTC OR EVIC INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6892 CMTC Or EVIC Inoperative POSSIBLE CAUSES - (F21) Fused ignition switch output (run/start) circuit open - (Z13) Electronic overhead module ground circuit open - Electronic overhead module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6893 1. (F21) FUSED IGNITION RUN/START CIRCUIT OPEN NOTE: Diagnose and repair any MIC, FCM, PCM, or Communication DTCs before proceeding. Turn the ignition off. Disconnect the Electronic Overhead Module harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output (Run/Start) circuit and ground. Q: Is the voltage below 0.5 volts? YES: Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. (Z13) ELECTRONIC OVERHEAD MODULE GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance between ground and the (Z13) Electronic Overhead Module Ground circuit. Q: Is the resistance above 5.0 ohms? YES: Repair the (Z13) Electronic Overhead Module Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Compass Test Failure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6894 COMPASS TEST FAILURE WHEN MONITORED With the ignition on. SET CONDITION The Electronic Overhead Module (EOM) display reads "FAILED SELF TEST." POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Depress and hold the RESET and C/T buttons while turning the ignition on. NOTE: This test may also be performed using the DRBIII(R). Q: Does the EOM or DRBIII(R) display "FAILED SELF TEST"? YES: Replace the EOM. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Distance to Empty Inaccurate or Wrong DISTANCE TO EMPTY INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Elapsed Ignition On Time Inaccurate or Wrong ELAPSED IGNITION ON TIME INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC OVERHEAD MODULE NOTE: - Diagnose and repair any FCM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the EOM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6895 configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. Temperature Display Inaccurate or Inoperative TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Electronic overhead module 1. AMBIENT TEMPERATURE SENSOR NOTE: - Diagnose and repair any FCM, EOM, PCM, or Communication DTCs before proceeding with this test. - The Ambient Temperature Sensor is hardwired to the FCM (Diesel), or to the PCM. Ambient temperature information is transmitted to the EOM via the PCI Bus. Turn the ignition off. Disconnect the Ambient Temperature Sensor harness connector. Measure the resistance of the Ambient Temperature Sensor using the following temperature/resistance values: 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.88 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms 50° C (122° F) Sensor Resistance = 3.33 - 3.88 Kilohms Q: Is the Ambient Temperature Sensor resistance measurement within the min/max specifications? YES: Go To 2 NO: Replace the Ambient Temperature Sensor. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6896 2. ELECTRONIC OVERHEAD MODULE Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test Turn the ignition off. Press and hold the C/T and Reset buttons. Turn the ignition on. NOTE: NOTE: The self test can also be performed using the DRBIII(R). Observe the EOM display at the conclusion of the self test. Q: Does the EOM display "Passed Self Test"? YES: Test Complete. NO: Replace and configure the EOM. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Trip Odometer Inaccurate or Wrong TRIP ODOMETER INACCURATE OR WRONG POSSIBLE CAUSES - Electronic overhead module 1. ELECTRONIC VEHICLE INFORMATION CENTER NOTE: - Diagnose and repair any FIDEM, PCM, or Communication DTCs before proceeding with this test. - Ensure that the OEM has been configured for the correct fuel tank size. Use the DRBIII(R) to verify or modify the fuel tank size configuration. Perform the EOM Self Test. See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection/Self-Diagnostic Test The self test can be performed with the DRBIII(R) or manually using the following procedure: Turn the ignition off. Press and hold the RESET and C/T buttons. Turn the ignition on. Continue to hold both buttons until the software version is displayed, then release the buttons. Observe the EOM display when the self test is complete. Q: Did the EOM display "FAILED SELF TEST"? YES: Replace and configure the Electronic Overhead Module. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Test Complete. All Door Locks Inoperative ALL DOOR LOCKS INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6897 All Door Locks Inoperative POSSIBLE CAUSES - DTC present - Fuse #22 open - (A941) Fuse B+ circuit open - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6898 Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock or Cluster related DTC's? YES: Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. FUSE #22 OPEN Test both sides of fuse #22 in the PDC. Q: Is there 12 volts on both sides of fuse #22? YES: Go To 3 NO: Replace the fuse if open and retry the system. If the fuse blows, locate and repair a short to the Instrument Cluster. The 12 volt supply to the fuse is a bus bar in the PDC. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. (A941) FUSED B+ CIRCUIT OPEN Turn the ignition off. Remove the instrument cluster. Measure the voltage between the (A941) Fused B+ circuit and ground (cavity 2 in the C1 connector to ground). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6899 Q: Is the voltage above 10.0 volts on the Fused B+ circuit? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the Fused B+ circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Automatic (Rolling) Door Locks Inoperative AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Door ajar switch status incorrect - TPS or VSS DTC's - Auto door locks not enabled - Instrument cluster Diagnostic Test 1. CHECK THE DOOR AJAR SWITCH STATUS Ensure all doors are closed. With the DRBIII, enter "Electro/Mech Cluster" then "Input/Output" and observe all of the Door Ajar states. Q: Does the DRBIII display CLOSED for any door ajar state? YES: Select the appropriate Door Ajar Circuit Shorted: NO: Go To 2 2. ANY TPS OR VSS RELATED DTC'S With the DRBIII read "Engine" and "Anti-Lock Brakes" DTC's. Q: Does the DRBIII display any Throttle Position Sensor or Vehicle Speed Sensor related DTC's? YES: Diagnose and repair the DTC's. NO: Go To 3 3. ENABLE AUTO DOOR LOCKS With the DRBIII, enter "Electron/Mech Cluster" then "Miscellaneous" and observe the rolling door lock status. Q: Does the DRBIII display ROLLING DOOR LOCKS: ENABLED YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: With the DRBIII, enable the Auto Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6900 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Cylinder Lock Switch Inoperative CYLINDER LOCK SWITCH INOPERATIVE Cylinder Lock Switch Inoperative POSSIBLE CAUSES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6901 DTC PRESENT - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch mux circuit open - (G163) Cylinder lock switch mux wire short to ground - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Turn the ignition on. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6902 Measure the voltage between (G163) Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6903 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Door Lock Inhibit Inoperative DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster Diagnostic Test 1. CHIME INOPERATIVE Turn the ignition off but leave the key in the ignition. Open the drivers door. Q: Does the chime sound? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Perform the test "KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE". See: Chime System/Key In Ignition and Drivers Door Open Chime Inoperative Driver Door Fails to Lock and Unlock DRIVER DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6904 Driver Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P1) Door unlock driver left front wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6905 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P1) Door Unlock Driver Left Front circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Driver Door lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6906 NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Driver Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P1) DOOR UNLOCK DRIVER LEFT FRONT WIRE OPEN Measure the resistance of the (P1) Door Unlock Driver Left Front circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P1) Door Unlock Driver Left Front wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Left Rear Door Fails to Lock & Unlock LEFT REAR DOOR FAILS TO LOCK AND UNLOCK Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6907 Left Rear Door Fails To Lock And Unlock POSSIBLE CAUSES - DTC present - (P393) Door lock driver left doors wire open - (P5) Door unlock driver left rear wire open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6908 - Door latch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks to diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (P5) Door Unlock Driver Left Rear circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P393) Door Lock Driver Left Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the left doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6909 Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (P393) DOOR LOCK DRIVER LEFT DOORS WIRE OPEN Disconnect the Left Rear Door Latch connector. Measure the resistance of the (P393) Door Lock Driver Left Doors circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P393) Door Lock Driver Left Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (P5) DOOR UNLOCK DRIVER LEFT REAR WIRE OPEN Measure the resistance of the (P5) Door Unlock Driver Left Rear circuit between the Instrument Cluster C1 connector and the Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (P5) Door Unlock Driver Left Rear wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test One Door Lock Motor Inoperative Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6910 ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Door lock driver or door unlock driver circuit open - Door latch Diagnostic Test 1. CHECK DOOR LOCK MOTOR CIRCUIT With the DRBIII(R), read DTCs. If there are any door lock related DTC's, refer to symptom list for problems related to Power Door Locks and diagnose and repair the DTC's. Disconnect the inoperative Door Latch connector. Connect a 12 volt test light between the Door Lock Driver and the Door Unlock Driver circuits in the latch connector. NOTE: Graphic shows Passenger Latch - all others similar. Operate the door locks several time in the lock and unlock positions from a door lock switch and observe the test light. Q: Does the test light illuminate brightly when the locks are actuated in both directions? YES: Replace the Door latch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the appropriate Door Lock Driver or Door Unlock Driver circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Doors Fail to Lock and Unlock - Quad Cab RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6911 Right Doors Fail To Lock And Unlock - Quad Cab POSSIBLE CAUSES - DTC present - (P392) Door lock driver right doors wire open - (G778) Door unlock driver right doors wire open - Door latch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6912 - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Does the DRBIII(R) display any Door Lock related DTC's? YES: Refer to symptom list for problems related to Power Door Locks and diagnose and repair DTC's. NO: Go To 2 2. INSTRUMENT CLUSTER Turn the ignition off. Disconnect the Instrument Cluster C1 connector. Connect a jumper wire between the (G778) Door Unlock Driver Right Doors circuit in the Instrument Cluster C1 connector and ground. Momentarily connect a fused jumper wire between the Fused B+ circuit and the (P392) Door Lock Driver Right Doors circuit in the Instrument Cluster C1 connector. Reverse the jumper wires to drive the motor in the opposite direction. Q: Did the Right Doors lock and unlock? YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6913 NO: Go To 3 3. (P392) DOOR LOCK DRIVER RIGHT DOORS WIRE OPEN Disconnect the Passenger Door Latch connector. Measure the resistance of the (P392) Door Lock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Go To 4 NO: Repair the (P392) Door Lock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G778) DOOR UNLOCK DRIVER RIGHT DOORS WIRE OPEN Measure the resistance of the (G778) Door Unlock Driver Right Doors circuit between the Instrument Cluster C1 connector and the Passenger Door Latch connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Door Latch. Perform BODY VERIFICATION TEST-VER 1. NO: Repair the (G778) Door Unlock Driver Right Doors wire for an open. Perform BODY VERIFICATION TEST VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test RKE Inoperative RKE INOPERATIVE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6914 POSSIBLE CAUSES - DTC present - Transmitter not programmed - RKE transmitter - Remote keyless entry module Diagnostic Test 1. DTC PRESENT With the DRBIII(R), read DTCs. Attempt to operate the door locks with the RKE transmitter. Q: Does the DRBIII(R) display RKE FOB BATTERY LOW? YES: Refer to symptom RKE FOB BATTERY LOW in this category. NO: Go To 2 2. 9001 TESTER AVAILABLE Q: Do you have access to the Miller Special Tool "9001 RF DETECTOR"? NO: Go To 3 YES: Go To 5 3. TRANSMITTER NOT PROGRAMMED Turn the ignition on. Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarmed Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Try the door locks using the Transmitter. Q: Does the RKE System operate properly? YES: Repair complete. Check with the customer to see if the other transmitters) are operating properly. They may have to be programmed also. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. SUBSTITUTE A KNOWN GOOD TRANSMITTER Secure a known good transmitter. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6915 With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, PROGRAM New Fob. Follow the instructions on the DRBIII screen. Programming mode will last for 30 seconds. To get out of Programming Mode sooner, press PAGE BACK. Lock and Unlock the vehicle using the transmitter. Q: Does the RKE System operate properly? YES: Replace the original transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. TEST TRANSMITTER WITH TESTER Using the 9001 RF Detector, follow the instructions on the back of the tester and test the transmitter several times. Q: Does the signal strength measure "STRONG"? YES: Go To 6. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the transmitter and program all transmitters that will be used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 6. PROGRAM RKE TRANSMITTER WITH THE DRBIII(R) Turn the ignition on Place transmission in the Park position. Ensure Vehicle Theft Security System (if equipped) is in Disarm Mode. With the DRBIII(R), select ELECTRO/MECH CLUSTER, MISCELLANEOUS, then PROGRAM New Fob. Follow the instructions on the screen. Exit PROGRAM RKE. Activate the Door Locks using the RKE Transmitter. NOTE: When repairs are complete, ensure all transmitters used with the vehicle have been programmed. Q: Did the door locks respond properly to the RKE transmitter commands? YES: Repair complete. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace the Remote Keyless Entry Module and reprogram all transmitters used with this vehicle. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Alarm Trips On Its Own ALARM TRIPS ON ITS OWN Diagnostic Test 1. LAST VTSS CAUSE With the DRBIII(R) in Inputs/Outputs, read the Last VTSS Cause state. Q: Were there any causes displayed? YES: Check for a possible intermittent condition with the circuit indicated by the DRBIII(R). Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: The condition that caused this symptom is currently not present. Inspect the related wiring harness for a possible intermittent condition. Look for any chafed, pierced, pinched or partially broken wires. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Cylinder Lock Switch INOP CYLINDER LOCK SWITCH INOP Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6916 Cylinder Lock Switch Inop POSSIBLE CAUSES - DTC present - (Z463) Cylinder lock switch ground open - (G163) Cylinder lock switch MUX circuit open - (G163) Cylinder lock switch MUX wire short to ground Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6917 - Cylinder lock switch - Instrument cluster Diagnostic Test 1. DTC PRESENT Turn the ignition on. With the DRBIII(R), read DTC's. Q: Are there any Power Door Lock related trouble codes? YES: Refer to symptom list for problems related to Power Door Locks. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. CYLINDER LOCK SWITCH VOLTAGE LOW Turn the ignition off. Disconnect the Cylinder Lock Switch connector. Measure the voltage between (G163) Cylinder Lock Switch MUX circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 3 NO: Go To 4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6918 3. (Z463) CYLINDER LOCK SWITCH GROUND OPEN Using a 12-volt test light connected to 12-volts, check the (Z463) Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (Z463) Ground circuit for an open. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 4. (G163) CYLINDER LOCK SWITCH MUX OPEN Turn the ignition off. Disconnect the Instrument Cluster C4 connector. Measure the resistance of the (G163) Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Go To 5 NO: Repair the (G163) Cylinder Lock Switch Mux circuit for an open. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 5. (G163) CYLINDER LOCK SWITCH MUX WIRE SHORT TO GROUND Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6919 Measure the resistance between Ground and the (G163) Cylinder Lock Switch Mux circuit in the Cluster C4 connector. Q: Is the resistance below 1000.0 ohms? NO: Replace the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test YES: Repair the (G163) Cylinder Lock Switch Mux circuit for a short to ground. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Driver Door Does Not Trip VTSS DRIVER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the DRIVER DOOR AJAR SW status. Open the driver door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom DRIVER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the driver's door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the driver door lock. Attempt to trip the VTSS by opening the drivers door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6920 Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Headlamps Fail to Flash When Alarm Is Tripped HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster 1. CHECK FCM DTCS AND HIGH BEAM HEADLAMP OPERATION Attempt to operate the exterior lamps with the headlamp switch. With the DRBIII(R), read FCM DTCs. Q: Were there any problems found? YES: Refer to symptom list for problems related to Exterior Lighting. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Horn Fails to Sound When Alarm Is Tripped HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster 1. HORN RELAY CONTROL CIRCUIT DTC ACTIVE Turn the ignition on. With the DRBIII(R), read FCM DTC's. Q: Does the DRBIII(R) display a HORN RELAY CONTROL CIRCUIT DTC active? YES: Refer to the Ignition, Power, Accessory category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 2 2. HORN CIRCUIT DIAGNOSTICS Q: Does the horn operate from the horn button? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Refer to symptom Horns Inoperative in the Ignition, Power, Accessory category. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Left Rear Door Does Not Trip VTSS (4 Door) LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6921 - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Left Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom LEFT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the left rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the left rear door lock. Attempt to trip the VTSS by opening the left rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Passenger Door Does Not Trip VTSS PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the passenger door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom PASSENGER DOOR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6922 2. ATTEMPT TO TRIP VTSS Open the passenger door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the passenger door lock. Attempt to trip the VTSS by opening the passenger door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Right Rear Door Does Not Trip VTSS (4 Door) RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster 1. DOOR AJAR STATE With the DRBIII(R), read the PASS DOOR AJAR SW status. Open the Right Rear door. Q: Does the DRBIII(R) display CLOSED? YES: Go To 2 NO: Refer to symptom RIGHT REAR AJAR CIRCUIT OPEN. See: Interior Lighting Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 2. ATTEMPT TO TRIP VTSS Open the right rear door window. Remove key from ignition switch. Use the RKE or power door lock switch to lock the doors then close all doors. Wait approximately 15 seconds for the VTSS indicator to flash at a slower rate indicating the Vehicle Theft Security System is armed. Manually unlock the right rear door lock. Attempt to trip the VTSS by opening the right rear door. Q: Did the VTSS trip when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6923 3. DISCONNECT BATTERY TO RESET FCM Turn the ignition Off to the lock position. Disconnect the negative battery cable wait 5 seconds then reconnect. Turn the ignition to the On position for 10 seconds then back Off to the lock position and remove key. Arm the VTSS and attempt to trip to alarming state by manually unlocking door and opening. Q: Did the VTSS trip to the alarming state when the door was opened? YES: Test complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test VTSS Will Not Arm Properly VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster 1. ATTEMPT TO ENABLE THE VTSS Turn the ignition Off to the lock position. Disconnect the battery negative cable wait 5 seconds then reconnect battery cable. Turn the ignition to the On position for 10 seconds, then back Off to the lock position and remove key. Close all doors. Using the key, lock the vehicle with the Driver Door Cylinder Lock Switch and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Go To 2 NO: Go To 3 2. VTSS NOT ENABLED Unlock the vehicle to disarm the VTSS. Ensure all doors are closed. Using the RKE key fob, lock the vehicle and observe the VTSS indicator. Q: Did the VTSS indicator flash rapidly, then flash at a slower rate indicating the VTSS is armed? YES: Test Complete. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. USE DRB TO COMMUNICATE WITH THE SKIM With the DRBIII(R), attempt to communicate with the SKIM. Q: Does the DRBIII(R) communicate with the SKIM? YES: Go To 4 NO: Refer to communication category for the related symptom(s). Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 4. DTC OR VTSS INHIBITORS Ensure the doors are closed. With the DRBIII(R), read the active DTC's and the ajar switch states. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6924 Q: Does the DRBIII(R) display any closed switches or related DTC's? YES: Refer to the Symptom List and diagnose the appropriate symptom in the DOOR AJAR or related category. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Go To 5 5. CYLINDER LOCK SWITCH CIRCUIT OPEN Turn the ignition on. With the DRBIII(R), read the Driver Cylinder Lock Switch MUX volts while turning the key in the driver door lock cylinder. Q: Did the MUX voltage change from approximately 5.0 volts to 4.0 for lock and 2.4 for unlock? YES: Replace and program the Instrument Cluster. Perform Body Verification Test - Ver 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 6 6. INSTRUMENT CLUSTER CYLINDER LOCK SWITCH VOLTAGE LOW Disconnect the Cylinder Lock Switch connector. Measure the voltage between Cylinder Lock Switch Mux circuit and ground. Q: Is the voltage between 4.6 and 5.2 volts? YES: Go To 7 NO: Go To 8 7. CYLINDER LOCK SWITCH GROUND OPEN Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 6925 Disconnect the Cylinder Lock Switch connector. Using a 12-volt test light connected to 12-volts, check the Ground circuit. Q: Does the test light illuminate brightly? YES: Replace the Cylinder Lock Switch. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Ground circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test 8. CYLINDER LOCK SWITCH MUX OPEN Disconnect the Cylinder Lock Switch connector. Disconnect the Instrument Cluster C2 connector. Measure the resistance of the Cylinder Lock Switch Mux circuit between the Switch connector and the Instrument Cluster connector. Q: Is the resistance below 5.0 ohms? YES: Replace the Instrument Cluster. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test NO: Repair the Cylinder Lock Switch Mux circuit for an open. Perform VTSS VERIFICATION TEST - 1A. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/VTSS Verification Test Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL ST/SLT/SLT+ 1. Remove the two screws (4) at each trailing edge of the fascia. 2. Remove the four push pin fasteners (5) from the upper edge of the close out panel. 3. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 4. Using a trim stick or equivalent, carefully remove the step pad (1). 5. Remove and discard the four push pin fasteners (5) and remove the fascia. SPORT 1. Raise and support the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 6931 2. Remove the three screws (3) at each trailing edge of the fascia. 3. Remove the five lower screws (8). 4. Remove and discard the four upper push pins (7). 5. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 6. Using a trim stick or equivalent, carefully remove the step pad (1). 7. Spread the fascia (2) out at the wheels and remove from the vehicle. INSTALLATION ST/SLT/SLT+ NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Install the fascia. 2. Position the close out panel and seat the 6 lower clips fully. 3. Install four new upper push pin fasteners (5). 4. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 5. Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia. SPORT Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 6932 NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Position the fascia (2) onto the bumper. 2. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 3. Install four new upper push pin fasteners (7). 4. Install the five lower screws (8). 5. Install the three screws (3) at each trailing edge of the fascia. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair Rear Bumper: Service and Repair REAR BUMPER REMOVAL 1. Raise and support the vehicle. 2. Remove the license plate. 3. Remove the bolts behind the plate. 4. Disconnect the license plate light electrical connectors. 5. Disconnect the trailer light connector electrical connection (if equipped). 6. Remove the two bolts along the front upper edge of the bumper near the frame tips. 7. Support the bumper with a suitable lifting device. 8. Remove the bolts attaching the bumper support brackets (4) to the trailer hitch (1). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Page 6936 1. Align the holes in the bumpers to the trailer hitch pins and install the bumper. 2. Loosely install the hitch bolts (2) in the support bracket (4). 3. Install the front upper edge to the trailer hitch bolts (2) and tighten to 54 N.m (40 ft.lbs.). 4. Install the license plate reinforcement to hitch bolts (2) and tighten to 54 N.m (40 ft.lbs.). 5. Tighten the left bumper bracket bolts (3) to 54 N.m (40 ft.lbs.). 6. Tighten the right bumper bracket bolts (3) to 54 N.m (40 ft.lbs.). 7. Connect the trailer light connector electrical connection (if equipped). 8. Connect the license plate light electrical connectors. 9. Install the license plate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair BODY VENT REMOVAL 1. Remove the rear cab trim panel, Refer to Trim Panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the door glass. 3. If equipped, disconnect the exterior handle wire lead (7) from the door wire harness connector (3). 4. Disconnect the actuator rods (6 and 8) for the door latch (5) from the exterior handle (1). 5. Remove the two nuts (2) that secure the exterior handle to the door (4) and remove the handle. INSTALLATION 1. Position the exterior handle (1) into the door (4). 2. Install the two nuts (2) that secure the exterior handle to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rods (6 and 8) for the door latch (5) to the exterior handle. 4. If equipped, connect the exterior handle wire lead (7) to the door wire harness connector (3). 5. Install the door glass. 6. Reconnect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair INTERIOR HANDLE ACTUATOR REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from interior door handle actuator (5) and the door latch (2), if necessary. 3. Remove the two nuts (4) that secure the interior door handle actuator to the door (1) and remove the actuator. INSTALLATION 1. Position the interior door handle actuator (5) onto the door (1). 2. Install the two nuts (4) that secure the interior door handle actuator to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (3) to the interior door handle actuator and the door latch (2), if removed. 4. Reposition the waterdam and install the door trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6962 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6963 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6969 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6970 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6971 Front Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6972 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6973 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6974 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6975 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Page 6976 Front Door Hinge: Service and Repair HINGE REMOVAL 1. Remove the door. 2. Using a grease pencil or equivalent, mark the hinge location and remove the bolts (3) and (4). INSTALLATION NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Install the hinges and bolts. 2. Tighten the upper hinge bolt (1) to hinge pillar to 28 N.m (21 ft.lbs.). 3. Tighten the lower hinge bolt (2) to hinge pillar to 28 N.m (21 ft.lbs.). 4. Tighten the remaining hinge to hinge pillar bolts (3) and (4) to 28 N.m (21 ft.lbs.). 5. Install the door. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams Front Door Latch: Diagrams Latch-Door-Driver (Power Locks) Latch-Door-Driver (Power Locks) Latch-Door-Passenger (Power Locks) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 6980 Front Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 N.m (30 in.lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 6981 Front Door Latch: Service and Repair LATCH REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from the door latch (2) and the interior door handle actuator (5) and remove the rod. 3. Disconnect the door wire harness connector (2) from the door latch (3). 4. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 6982 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the actuator rod (3) to the door latch (2) and the interior door handle actuator (5). 5. Reposition the waterdam to the door (1) and install the door trim panel. 6. If necessary, adjust the latch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures Front Door Panel: Procedures REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6987 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6988 Front Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6989 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Waterdam WATERDAM REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6990 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the B-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 N.m (21 ft.lbs.). 4. Verify correct door and latch position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 6994 Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the B-pillar and remove the striker. INSTALLATION 1. Position the door latch striker (1) onto the B-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the B-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 N.m (21 ft.lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6999 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer A-PILLAR WEATHERSTRIP RETAINER REMOVAL 1. Remove the drip rail weatherstrip retainer (1). 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7000 Front Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7001 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7002 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7003 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7004 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7005 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7006 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7007 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer DRIP RAIL WEATHERSTRIP RETAINER REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7013 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7014 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7015 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7016 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7017 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7018 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7019 2. Install the door trim panel (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7024 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7025 Front Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7026 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7027 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7028 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove the front glass run channel, Refer to Window Track. 2. Disconnect the actuator rod (1) from the exterior door handle (2). 3. Remove the two nuts (3) that secure the exterior door handle to the door and remove the handle. INSTALLATION 1. Position the exterior handle (2) into the door. 2. Install the two nuts (3) that secure the exterior handle to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (1) to the exterior handle. 4. Install the front glass run channel, Refer to Window Track. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair INTERIOR HANDLE ACTUATOR REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (2) from interior door handle actuator (3). 3. Remove the two bolts (1) that secure the interior door handle actuator to the door and remove the actuator. INSTALLATION 1. Position the interior door handle actuator (3) onto the door. 2. Install the two bolts (1) that secure the interior door handle actuator to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (2) to the interior door handle actuator. 4. Reposition the waterdam and install the door trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7045 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7046 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7052 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7053 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7054 Rear Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7055 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7056 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7057 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7058 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7059 Rear Door Hinge: Service and Repair HINGE REMOVAL NOTE: - It is not necessary to remove the door to replace the hinges if they are replaced one at a time. - The epoxy coated washers should not be removed from the hinge. If the washers are removed the door may have to be re-adjusted. 1. Open the front door UPPER HINGE 1. Using a grease pencil or equivalent, mark the position of the hinge (2) on the door and b-pillar. 2. Remove the nut (1) and bolt (9) attaching the hinge (2) to the door. 3. Remove the three bolts (6) attaching the hinge to the b-pillar and remove the hinge. LOWER HINGE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7060 1. Using a grease pencil or equivalent, mark the position of the hinge on the door and b-pillar. 2. Remove the lower b-pillar trim. Refer to Trim Panel. 3. Remove the nut (1) and bolt (9) attaching the hinge to the door. 4. Remove the two bolts (5) attaching the hinge to the b-pillar. 5. From the inside of the vehicle remove the remaining bolt (4) attaching the hinge to the b-pillar and remove the hinge. INSTALLATION UPPER HINGE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7061 1. Install the hinge to door washers, if there were removed previously, nut (1) and bolt (9) and tighten to 28 N.m (21 ft.lbs.). 2. Tighten the upper hinge bolt (2) to 28 N.m (21 ft.lbs.). 3. Tighten the upper hinge bolt (1) to 28 N.m (21 ft.lbs.). 4. Tighten the upper hinge bolt (3) to 28 N.m (21 ft.lbs.). 5. Adjust the door if needed. LOWER HINGE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7062 1. Install the hinge and install the b-pillar bolts. 2. Tighten the upper hinge bolt (2) to 28 N.m (21 ft.lbs.). 3. Tighten the upper hinge bolt (1) to 28 N.m (21 ft.lbs.). 4. Tighten the upper hinge bolt (3) to 28 N.m (21 ft.lbs.). 5. Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28 N.m (21 ft.lbs.). 6. Adjust the door if needed. 7. Install the lower b-pillar trim. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams Rear Door Latch: Diagrams Latch-Door-Left Rear (Base) Latch-Door-Left Rear (Power Locks) Latch-Door-Right Rear (Base) Latch-Door-Right Rear (Power Locks) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7066 Rear Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 N.m (30 in.lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7067 Rear Door Latch: Service and Repair LATCH REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (1) from the interior door handle actuator (2) and the door latch (5) and remove the rod. 3. Disconnect the two actuator rods (3 and 4) from the door latch. 4. Disconnect the door wire harness connector (2) from the door latch (3). 5. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7068 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the two actuator rods (3 and 4) to the door latch (5) 5. Connect the actuator rod (1) to the door latch and the interior door handle actuator (2). 6. Reposition the waterdam to the door and install the door trim panel. 7. If necessary, adjust the latch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures Rear Door Panel: Procedures Trim Panel REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator (1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7073 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Water Dam REMOVAL 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7074 3. Carefully remove the waterdam (1) from around the perimeter of the rear door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7075 Rear Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator(1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (2) using a window crank removal tool (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7076 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Waterdam WATERDAM REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7077 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the rear door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the C-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 N.m (21 ft.lbs.). 4. Verify correct door and latch position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 7081 Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the C-pillar and remove the striker. INSTALLATION 1. Position the door latch striker (1) onto the C-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the C-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 N.m (21 ft.lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7086 Rear Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7087 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7088 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7089 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7090 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7091 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7092 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7098 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7099 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7100 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7101 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7102 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7103 2. Install the door trim panel (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures Manual REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (4) and the sight window (5) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7108 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N·m (89 in. lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Power REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7109 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (4) and the sight window (5) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7110 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7111 Rear Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7112 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7113 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7114 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding . Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open the fuel filler door (1). 2. Remove the two bolts (2) that secure the fuel filler door to the cargo box and remove the door. INSTALLATION 1. Position and align the fuel filler door (1) to the cargo box. 2. Install the two bolts (2) that secure the fuel filler door to the cargo box. Tighten the bolts to 9 N.m (80 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges can be replaced one at a time. REMOVAL 1. Remove the cowl grille. 2. Using a grease pencil or equivalent, mark the position of the hood hinge (3) on the hood for the hinge being serviced. 3. Support the hood and disconnect the support cylinder from the hood, Refer to Hood Shock / Support. 4. Remove the two nuts that secure the hood to the hood hinge. 5. Remove the bolt (2) that secures the front fender (1) to the hood hinge. 6. Remove the wheelhouse splash shield. 7. Remove the bolts (3) that secure the hood hinge (2) to the fender rail (1). 8. Slide the hood hinge forward and remove the hinge. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 7122 1. Position the hood hinge (2) onto the fender rail (1) and slide it rearward to its installed location. 2. Install the bolts (3) that secure the hood hinge to the fender rail. Tighten the bolts to 20 N.m (15 ft.lbs.). 3. Install the bolt (2) that secures the front fender (1) to the hood hinge (3). Tighten the bolt to 12.5 N.m (9 ft.lbs.). 4. Loosely install the two nuts that secure the hood to the hood hinge. 5. Align the hood to the hood hinge using the reference marks made during the Removal procedure and tighten the nuts to 23 N.m (17 ft.lbs.). 6. Install the support cylinder. 7. If required, adjust the hood to the correct position. 8. Install the wheelhouse splash shield. 9. Install the cowl grille. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch Hood Latch: Service and Repair Latch LATCH REMOVAL 1. Using a grease pencil or equivalent, mark the position of the hood latch (1) on the upper radiator crossmember. 2. Remove the two bolts (3) that secure the hood latch to the upper radiator crossmember. 3. Disconnect the hood latch cable (2) from the hood latch and remove the latch. INSTALLATION 1. Connect the hood latch cable (2) to the hood latch (1). 2. Position the hood latch to the upper radiator cross-member and loosely install the two bolts (3) that secure the latch to the crossmember. 3. Align the hood latch to the upper radiator cross-member using the reference marks made during the Removal procedure and tighten the bolts to 11 N.m (8 ft.lbs.). 4. If required, adjust the hood to the correct position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 7127 Hood Latch: Service and Repair Latch Striker/Secondary Catch LATCH STRIKER/SECONDARY CATCH REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 N.m (8 ft.lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE/HANDLE ASSEMBLY REMOVAL 1. Remove the hood latch. 2. Remove the battery tray from the left side of the engine compartment. 3. Remove the three hood release cable retainers from the upper radiator crossmember and the left fender rail. 4. From inside the vehicle, remove the two bolts (1) that secure the hood release handle (2) to the instrument panel bracket (3). 5. Remove the grommet (4) from the cowl panel and remove the hood release cable and handle assembly. INSTALLATION 1. Route the hood release cable through the cowl panel and install the grommet (4). 2. Position the hood release handle (2) onto the instrument panel bracket (3). 3. Install the two bolts (1) that secure the hood release handle to the instrument panel bracket. Tighten the bolts to 9 N.m (80 in.lbs.). 4. Route the hood release cable along the left fender rail and the upper radiator crossmember and install the three hood release cable retainers. 5. Install the battery tray to the left side of the engine compartment. 6. Install the hood latch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair SUPPORT CYLINDER REMOVAL NOTE: The hood support cylinders can be replaced one at a time. 1. Open and support the hood. CAUTION: Do not pull on the hood support cylinders at the middle of the support cylinder during removal. Failure to follow this caution can result in damage to the hood support cylinders. 2. Using a small flat bladed tool, or equivalent (3), release the retaining clip (2) at each end of the support cylinder while carefully pulling the ball socket (1) away from the ball stud (4). NOTE: Lift the clips (1) only enough to release the ball studs (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 7134 3. Disconnect the hood support cylinder (5) from the hood (1) and the fender rail (3). 4. If required, remove the upper ball stud (2) from hood and the lower ball stud (4) from the fender rail. INSTALLATION 1. If removed, install the upper ball stud (2) onto the hood (1) and the lower ball stud (4) onto the fender rail (3). Install the ball studs securely. CAUTION: Do not push on the hood support cylinders at the middle of the support cylinder during installation. Failure to follow this caution can result in damage to the hood support cylinders. NOTE: Install the hood support cylinders with the cylinder end connected to the hood as shown. - If required, only release each retaining clip enough to install the ball socket onto the ball stud. 2. Install the hood support cylinder (5) over the upper and lower ball studs and fully engage the retaining clips. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Service and Repair Hood Striker: Service and Repair LATCH STRIKER/SECONDARY CATCH REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 N.m (8 ft.lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES NOTE: Mega Cab model shown in the illustration. Exterior name plates and decals for all other cab models are similar. Exterior name plate and decal usage vary by model. REMOVAL Name Plates 1. As a guide for installation, apply a length of masking tape on the body (1), parallel to the top edge and, to one end of the name plate or decal (2) being removed. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the name plate or decal with a heat lamp or heat gun. NOTE: The exterior name plates are attached to the body with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the name plate or decal from the body panel, as necessary. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Page 7142 Name Plates 1. Thoroughly clean all residue from the name plate or decal attachment areas of the body (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the name plate or decal and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of name plate or decal (2) and position the name plate or decal onto the body using the previously installed guide tape. NOTE: To ensure proper name plate or decal adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each name plate or decal. 4. Install the name plate or decal onto the body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair BODY SIDE MOLDINGS NOTE: Quad Cab model shown in the illustration. Body side moldings for Regular cab models are similar. REMOVAL 1. As a guide for installation, apply a length of masking tape on the rocker panels (1), parallel to the top edge and, to one end of the body side molding (2 and 3) being removed CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the body side moldings with a heat lamp or heat gun. NOTE: The body side moldings are attached to the cab with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the moldings from the rocker panels, as necessary. INSTALLATION 1. Thoroughly clean all residue from the molding attachment areas of the rocker panels (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Page 7149 NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side molding and rocker panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of the body side molding (2 and 3) and position the molding onto the rocker panel using the previously installed guide tape. NOTE: To ensure proper molding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each body side molding. 4. Install the body side molding onto the rocker panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Open the hood and disengage any wiring or component retaining clips from the front splash shield (4) (depending on application and shield being serviced). 2. Raise and support the vehicle. 3. Remove the eight screws (3) that secure the front splash shield to the fender rail (1) and the front fender (2). 4. Disconnect the front splash shield from the support bracket located on the front bumper and remove the splash shield. INSTALLATION 1. Install the front edge of the front splash shield (4) into the support bracket located on the front bumper. 2. Position the front splash shield onto the fender rail (1) and the front fender (2). 3. Install the eight screws (3) that secure the front splash shield to the fender rail and the front fender. Tighten the screws to 5 N.m (44 in.lbs.). 4. Lower the vehicle and engage any wiring or component retaining clips to the front splash shield (depending on application and shield being serviced). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Raise and support the vehicle. 2. Remove the three screws (2) that secure the rear splash shield (3) to the cargo box (1) and remove the splash shield. INSTALLATION 1. Position the rear splash shield (3) onto the cargo box (1). 2. Install the three screws (2) that secure the rear splash shield to the cargo box. Tighten the screws to 5 N.m (44 in.lbs.). 3. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair Body / Frame Mount Bushing: Service and Repair BODY ISOLATORS NOTE: Quad Cab model shown in the illustration. Body isolators for Regular cab models are similar. REMOVAL 1. Loosen all cab to frame mounting bolts (5) (six Regular cab, eight Quad Cab). 2. Remove the mounting bolts and rebound cushions (3) as necessary. NOTE: If servicing the rear isolators (2), remove the reinforcement plates (6) and the washers (4). 3. Using a floor jack and wooden block under the cab sill (1), lift the body to gain access to the isolators and remove the isolators as necessary. INSTALLATION 1. Position the isolators (2) under the cab as necessary. CAUTION: If servicing the rear isolators, install the reinforcement plates (6) and the washers (4). 2. Lower the cab onto the isolators and install the mounting bolts (5) and rebound cushions (3) as necessary (six Regular cab, eight Quad Cab). 3. Tighten the mounting bolts to 81 N.m (60 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair TRANSMISSION CROSSMEMBER REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (3-if equipped). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 7167 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles-Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles-Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 7168 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft.lbs.). 2. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft.lbs.). 4. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 5. Remove the transmission support (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 7169 6. Install the transfer case skid plate (3-if equipped). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate Skid Plate: Service and Repair Front Skid Plate FRONT SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts (3). 3. Slide skid plate (2) back off of the crossmember (1) and remove. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 7174 1. Snap the rear tabs over the front crossmember (1) and install the skid plate (2). 2. Install the bolts (3) and tighten to 34 N.m (25 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 7175 Skid Plate: Service and Repair Transfer Case Skid Plate TRANSFER CASE SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Support the skid plate (3) and remove the bolts (4). 3. Remove the skid plate (3). 4. Support the skid plate crossmember (2) and remove the bolts (1). 5. Remove the skid plate crossmember (2). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 7176 1. Install the skid plate crossmember (2) and bolts (1). 2. Tighten the bolts (1) to 34 N.m (25 ft.lbs.). 3. Install the skid plate (3) and bolts (4). 4. Tighten the bolts (4) to 34 N.m (25 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7180 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft.lbs.). 3. Connect all wire harness support push pins. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7181 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft.lbs.). 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Grille: Service and Repair Grille GRILLE REMOVAL 1. Open the hood (2) and remove the six screws (5) that secure the grille (3) to the grille frame (4). 2. Remove the six nuts (1) that secure the grille to the hood and remove the grille. 3. If required, remove the grille frame from the hood. INSTALLATION 1. If removed, install the grille frame (4). 2. Position and align the grille (3) onto the hood (2) 3. Install the six nuts (1) that secure the grille to the hood. Tighten the nuts to 5 N.m (44 in.lbs.). 4. Install the six screws (5) that secure the grille to the grille frame. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille > Page 7189 Grille: Service and Repair Grille Frame GRILLE FRAME REMOVAL 1. Remove the grille. 2. Remove the six screws (3) that secure the grille frame (2) to the hood (1) and remove the frame. INSTALLATION 1. Position the grille frame (2) onto the hood (1). 2. Install the six screws (3) that secure the grille frame to the hood. Tighten the screws to 5 N.m (44 in.lbs.). 3. Install the grille. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair Arm Rest: Service and Repair CENTER ARMREST/SEAT BACK REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Remove the center seat. 3. Disconnect the storage bin/cushion cover j-straps and position aside. 4. Remove and discard the hinge bolts (2) and separate the seat back from the storage bin/cushion (1). INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Install the seat back onto the storage bin/cushion (1) and install new hinge bolts (2). 3. Tighten the hinge to storage bin/cushion bolts (2) to 25 N.m (18 ft.lbs.). 4. Connect the storage bin/cushion cover j-straps. 5. Install the center seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair REMOVAL 1. Open the ash receiver (3) and apply force in a downward motion to disengage the locking tabs (1) from the instrument panel (2). 2. Roll the ash receiver further downward and remove it from the instrument panel. INSTALLATION 1. Position the bottom of the ash receiver (3) into the opening of the instrument panel (2). 2. Pivot the ash receiver upward and fully seat the retaining clips (1) into the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Cargo Cover > Component Information > Technical Service Bulletins > Accessories/Body - Correct Tonneau Cover Installation Cargo Cover: Technical Service Bulletins Accessories/Body - Correct Tonneau Cover Installation NUMBER: 23-027-05 GROUP: Body DATE: May 03, 2005 SUBJECT: Tonneau Cover Installation MODELS: 2005 (DR) Ram Truck DISCUSSION: The MOPAR Snapless Tonneau Cover, p/n 82208129AB or 82208130AB may become damaged if the installation instructions are not carefully followed. Damage can lead to poor fit and customer dissatisfaction. The instructions included in the kit have been revised to include additional warnings. The information included in the new instructions is highlighted below: Use care when assembling the tonneau cover frame. The frame must be assembled in place, on the pick up box. Do not assemble the frame on the floor and attempt to lift the assembly on to the pick up box. The rear loops sewn on to the corners of the tonneau cover are intended to aid in the removal of the cover. Do not use the tabs as an installation aid to stretch the cover. When installing the fabric on to the frame, the installation sequence is important for ease of installation. Always start at the rear. Unroll the fabric and pull it rearward, gently stretching the fabric. Start at the center of the tailgate so that the MOPAR logo is directly above the center of the tailgate handle. Insert the plastic retainer in to the slot on the frame and work the plastic retainer into the slot from the center outward to the corner. Do the same for the other side. After the entire length of the rear retainer is secure, move to one of the front corners and start the plastic retainer into the frame slot. Work rearward until the entire side is secure, then repeat this for the other side. It is not necessary to use the removal loops if this procedure is followed. To remove the cover, start at the corner with the removal loop. Pull the loop downward at a 45 degree angle until the plastic retainer disengages from the frame slot. Do not pull up on the loop. Slowly disengage the ENTIRE rear of the Tonneau Cover from the Frame. You now have removed the tension in the tonneau fabric, proceed to disengage both sides of the tonneau from the frame. The tonneau then can be rolled up and secured with two (2) straps with buckles attached to the tonneau. All components contained in the kit are available through MOPAR. Replacement parts are listed in STAR PARTS. It is not necessary to replace the entire kit if individual parts are damaged or lost. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair CARPETS AND FLOOR MATS NOTE: Carpet for Quad Cab model shown. Regular cab similar. REMOVAL 1. Remove the front seats. 2. If equipped, remove the floor console. 3. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear trim panel (4). 4. On Quad Cab models, remove the rear seats (1). 5. On Quad Cab models, remove the rear cup holder (2) using a trim stick C-4755 or equivalent. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7204 6. Remove the lower B-pillar trim panels, Refer to Trim Panel. 7. On Quad Cab models, remove the bolt that secures the lower seat belt anchor to the floor panel near the B-pillars. 8. Remove the retaining screw (1) that secures the jack assembly (2) to the floor panel (3) and remove the jack assembly. 9. Remove the two bolts (4) that secure the jack assembly to the floor panel. 10. For trucks equipped with a scissor type jack, remove the bolts (1) and remove the jack (2). 11. Remove the screws and remove the load floor storage strap snaps (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7205 12. On Quad Cab models, remove the eleven pushpin fasteners (1) that secure the rear of the carpet (2) to the floor panel (3). 13. Remove the carpet from the vehicle. INSTALLATION 1. Position the carpet (2) into the vehicle. 2. On Quad Cab models, install the eleven push-pin fasteners (1) that secure the carpet to the floor panel (3). 3. Install the load floor storage snaps and screws (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7206 4. On trucks equipped with a scissor jack, install the jack and install the bolts (1). 5. Install the two bolts (4) that secure the jack assembly (2) to the floor panel (3). 6. Position the jack assembly onto the two bolts and install the retaining screw (1). Tighten the screw securely. 7. On Quad Cab models, install the bolt that secures the lower seat belt anchors the floor panel near the B-pillars. Tighten the bolt to 40 N.m (30 ft.lbs.). 8. Install the lower B-pillar trim panels. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7207 9. On Quad Cab models, install the rear seat (1). 10. On Quad Cab models, install the rear cup holder (2). 11. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 N.m (55 in.lbs.). 12. If equipped, install the floor console. 13. Install the front seats. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 Console: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 Console: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 8w-49-3 (NGC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 8w-49-4 (SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 8w-49-5 (Except SRT) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7236 Console: Service and Repair FLOOR CONSOLE REMOVAL Mini Floor Console 1. If equipped, remove the 4WD gear shift boot. 2. If equipped with a manual transmission, remove the transmission gear shift lever extension. 3. Remove the console inserts, if equipped. 4. Remove the bolts (2) that secure the rear console (1) to the floor panel. 5. Lift up the rear of the floor console to clear the gear shift lever, if equipped. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7237 6. Remove the bolts (2) and separate the front console (3) from the floor. 7. Separate the front clips (1) and remove the mini console. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. 2. Using a trim stick C-4755 or equivalent, separate the seven front console bezel clips (2), lift up the back of the bezel (1) and remove. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7238 3. Remove the bolts (1) and lift the rear of the base up to release the front guide pins (5). 4. Remove the front base (2). NOTE: Do not reuse the seat fasteners, always replace with new ones. 5. Remove and discard the front bolts (4). 6. Position the seats forward, remove the rear bolts (2) and discard. 7. Disconnect the 12 v power supply electrical connector (3-if equipped). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7239 8. Fold the seat backs forward and roll the seat assembly (1) back in the vehicle. 9. Remove the nuts (2) attaching the center seat console (1) to the drivers seat and the passenger seat and discard. 10. Remove the nuts (4) attaching the center console (2) to the drivers seat (3) and the passenger seat in the rear of the seat and discard. 11. Disconnect the electrical connector (1-if equipped). 12. Roll the seat assembly forward and remove the center seat console. INSTALLATION Mini Floor Console Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7240 1. Position the console and seat the front clips (1) fully. 2. Install the bolts (2). 3. Install the bolts (2) that secure the rear console (1) to the floor panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7241 4. Install the inserts. 5. Install the gear shift lever extension. 6. Install the 4WD gear shift boot. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Position the center seat console onto the front seat assembly and roll the seat assembly back in the vehicle. 3. Install new nuts (4) attaching the center console to the drivers (3) and passenger seat. 4. Connect the electrical connector (1-if equipped). 5. Tighten the nuts (4) to 25 N.m (18 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7242 6. Install new nuts (2) attaching the center console (1) to the drivers and passenger seat. 7. Tighten the nuts to 25 N.m (18 ft.lbs.). 8. Connect the electrical connector (3 and 5-if equipped). 9. Roll the seat assembly forward and install new rear bolts (2). 10. Connect the 12 v power supply electrical connector (3-if equipped). 11. Tighten the rear bolts to 40 N.m (30 ft.lbs.). 12. Fold the seat backs up and slide the seats to the rear. 13. Install new front bolts (4) and tighten to 28 N.m (21 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: - A storage bin replaces the cup holder in the instrument panel when the vehicle is equipped with a floor console. - If the cup holder is binding or sticking. 1. Remove the center bezel. 2. Remove the airbag control module cover. 3. Remove the four screws (1) that secure the cup holder (2) to the instrument panel. 4. Open the cup holder (2) and remove the two screws (1) that secure the cup holder to the instrument panel. 5. Remove the cup holder from the vehicle. Cup Holder Binds or Sticks Repair Procedure Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Page 7250 1. Using a trim stick C-4755 or equivalent, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (3). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front, if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. 4. The ACM wire harness (1) runs rearward along the left side of the tunnel under the carpet. Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed, and complete the repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Page 7251 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely inspect the metal bracket (1) where the cup holder fasteners attach as shown. If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. INSTALLATION NOTE: A storage bin replaces the cup holder in the instrument panel when the vehicle is equipped with a floor console. 1. Position the cup holder (2) into the instrument panel. 2. Install the four screws (1) that secure the cup holder to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Page 7252 3. Open the cup holder (1) and install the two screws (2) that secure the cup holder to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.) . 4. Install the center bezel. 5. Install the airbag control module cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Glove Compartment: Service and Repair Glove Box REMOVAL 1. Open the glove box (1). 2. Release the two glove box stops (2) and lower the glove box downward past the stops. 3. Disengage the glove box hinges from the instrument panel and remove the glove box. INSTALLATION 1. Engage the hinges of the glove box (1) to the instrument panel. 2. Press downward on the back edge of the glove box bin and raise the glove box past the two stops (2). 3. Close the glove box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 7257 Glove Compartment: Service and Repair Glove Box Latch Replacement REMOVAL 1. Remove the glove box and place it on a workbench. 2. Remove the 15 screws (1) that secure the glove box bin (2) and the inner glove box door panel (3) to the outer glove box door panel (4). 3. Remove the glove box bin and the inner glove box door panel from the outer glove box door panel. 4. Remove the two screws (1) that secure the glove box latch (2) to the outer glove box door panel (3) and remove the latch. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 7258 1. Position the glove box latch (2) into the outer glove box door panel (3). 2. Install the two screws (1) that secure the glove box latch to the outer glove box door panel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Position the inner glove box door panel (3) and the glove box bin (2) onto the outer glove box door panel (4). 4. Install the fifteen screws (1) that secure the inner glove box door panel and the glove box bin to the outer glove box door panel. Tighten the screws to 2 N.m (17 in.lbs.). 5. Install the glove box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER NOTE: Headliner for Quad Cab model shown. Regular cab similar. REMOVAL 1. Remove the A-pillar trim panels, Refer to Trim Panel. 2. Remove the upper B-pillar trim panels, Refer to Trim Panel. 3. On Quad Cab models, remove the upper C-pillar trim panels, Refer to Trim Panel. 4. Disconnect the wire harness connector (1) located at the left A-pillar from the headliner wire harness (2). 5. Disconnect the headliner wire harness connector (3) from the inside rear view mirror. 6. Remove the overhead console. 7. Remove the sun visors (4). 8. Remove the sun visor supports (5). 9. Remove the dome lamp (6). 10. Remove the two coat hooks (7). 11. Lower the rear of the headliner (9) downward from the roof panel (10) and disconnect the headliner wire harness connector (8) from the center high mounted stop lamp. 12. Lower the front of the headliner downward and remove the headliner through the passenger door opening. INSTALLATION 1. Position the headliner (9) into the vehicle through the passenger door opening. 2. Connect the headliner wire harness connector (8) to the center high mounted stop lamp. 3. Raise the rear of the headliner upward and install the two coat hooks (7). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7262 4. Raise the front of the headliner upward and install the sun visor supports (5). 5. Install the sun visors (4). 6. Install the dome lamp (6). 7. Install the overhead console. 8. Connect the headliner wire harness connector (3) to the inside rear view mirror. 9. Connect the headliner wire harness (2) to the wire harness connector (1) located at the left A-pillar. 10. On Quad Cab models, install the upper C-pillar trim panel. 11. Install the upper B-pillar trim panels. 12. Install the upper A-pillar trim panels. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor SUN VISOR REMOVAL 1. Remove the three screws (1) that secure each sun visor (2) to the roof panel and remove the visor from the headliner (3). 2. If equipped, disconnect the wire harness connector for the illuminated vanity mirror (4). INSTALLATION 1. If equipped, connect the wire harness connector for the illuminated vanity mirror (4). 2. Position the sun visor (2) onto the headliner (3). 3. Install the three screws (1) that secure each sun visor to the roof panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 7267 Sun Visor: Service and Repair Sun Visor Support SUN VISOR SUPPORT REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the release clip (3) as shown and remove the sun visor support (1) from the headliner (2) INSTALLATION 1. Position the sun visor support (1) through the headliner (2) and fully seat the base of the support to the roof panel. 2. Engage the release clip (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7272 Trim Panel: Removal and Replacement Cowl Trim COWL TRIM REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the cowl trim panel (1) from the retainer clips (2) in the door sill (3). 2. Pull the cowl trim panel rearward and remove it from the vehicle. INSTALLATION 1. Position the cowl trim panel (1) onto the door sill (3). 2. Push the cowl trim panel forward and then engage the retaining tabs that secure the sill trim panel to the rear door sill. Front Door Trim Panel TRIM PANEL REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7273 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7274 INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Load Floor LOAD FLOOR REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7275 1. Move the rear seat cushion (1) to the up position. 2. Remove the two nuts (2) that secure the rear of the load floor (3) to the floor panel. 3. Move the load floor (2) to the up position. 4. Remove the two bolts (3) that secure the load floor to the floor panel (1) and remove the load floor. 5. If required, remove the support cylinder (4), Refer to Utility Storage Compartment. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7276 1. If removed, install the load floor support cylinder (4). 2. Position the load floor (2) into the vehicle and install the two bolts (3) that secure it to the floor panel (1). Tighten the bolts to 40 N.m (30 ft.lbs.). 3. Move the load floor (3) to the down position and install the two nuts (2) that secure the load floor to the floor panel. Tighten the nuts to 25 N.m (18 ft.lbs.). 4. Move the rear seat cushion (1) to the down position. A-Pillar Trim A-PILLAR TRIM/GRAB HANDLE REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7277 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the a-pillar trim panel (2). 2. Remove the two bolts (4) that secure the a-pillar trim panel to the a-pillar (1) and remove the trim panel. INSTALLATION 1. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel. 2. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 6 N.m (55 in.lbs.). 3. Close the two fastener covers (3) located in the A-pillar trim panel. B-Pillar Grab Handle B-PILLAR GRAB HANDLE REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7278 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. INSTALLATION 1. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 N.m (55 in.lbs.). 2. Close the two fastener covers (2) located on the grab handle. B-Pillar Lower Trim B-PILLAR LOWER TRIM REMOVAL REGULAR CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7279 1. Remove the cowl trim panel, Refer to Trim Panel. 2. Remove the upper B-pillar trim panel, Refer to Trim Panel. 3. Remove the bolt (2) that secures the seat belt (1) to the bottom of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (3) to the B-pillar. 5. Remove the seat belt from the lower B-pillar trim panel through the slot provided and remove the trim panel. QUAD CAB 1. Remove the cowl trim panel, Refer to Trim Panel. 2. Remove the rear door sill trim cover, Refer to Trim Panel. 3. Remove the upper B-pillar trim panel, Refer to Trim Panel. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (1) to the B-pillar (2). 5. Remove the seat belt (3) from the lower B-pillar trim panel through the slot provided and remove the trim panel. INSTALLATION REGULAR CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7280 1. Route the seat belt (1) through the slot in the lower B-pillar trim panel (3) and position the trim panel to the B-pillar (4). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt to the bottom of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the upper B-pillar trim panel. 5. Install the cowl trim panel. QUAD CAB 1. Route the seat belt (3) through the slot in the lower B-pillar trim panel (1) and position the trim panel to the B-pillar (2). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the upper B-pillar trim panel. 4. Install the rear door sill trim cove, Refer to Trim Panel. 5. Install the cowl trim panel. B-Pillar Upper Trim B-PILLAR UPPER TRIM REMOVAL REGULAR CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7281 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. QUAD CAB 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7282 3. Remove the cap (1) and the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. INSTALLATION REGULAR CAB 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7283 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. 5. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 N.m (55 in.lbs.). 6. Close the two fastener covers (2) located on the grab handle. C-Pillar Lower Trim C-PILLAR LOWER TRIM REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7284 1. Remove the upper C-pillar trim panel, Refer to Trim Panel. 2. Remove the bolt (3) that secures the seat belt (2) to the bottom of the C-pillar (4) and position the seat belt out of the way. 3. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower C-pillar trim panel (1) to the C-pillar. 4. Remove the seat belt from the lower C-pillar trim panel through the slot provided and remove the trim panel. INSTALLATION 1. Route the seat belt (2) through the slot in the lower C-pillar trim panel (1) and position the trim panel to the C-pillar (4). 2. Engage the retaining tabs that secure the lower C-pillar trim panel to the C-pillar. 3. Install the bolt (3) that secures the seat belt to the bottom of the C-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the upper C-pillar trim panel. C-Pillar Upper Trim C-PILLAR UPPER TRIM REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7285 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the C-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper C-pillar trim panel (5) to the C-pillar and remove the trim panel. INSTALLATION 1. Position the upper C-pillar trim panel (5) to the C-pillar (4). 2. Engage the retaining tabs that secure the upper C-pillar trim panel to the C-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the C-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. Rear Cab Back Panel Trim REAR CAB BACK PANEL TRIM REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7286 1. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear cab trim panel (4). 2. If equipped, using a trim stick C-4755 or equivalent, disengage the latch (4) for the utility hook cover (3) and open the cover to gain access to the screw (1) that secures the utility hook (2) to the rear cab back panel. 3. On Regular cab models, remove the lower B-pillar trim panels, Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7287 4. On Regular cab models, remove the utility hook (3) or the storage bin latch (4) (depending on application) from the rear cab trim panel (1) and remove the trim panel. 5. On Quad Cab models, remove the child seat tether straps from the rear cab back panel (2). 6. On Quad Cab models, remove the center seat belt trim bezel. 7. On Quad Cab models, remove the lower C-pillar trim panels, Refer to Trim Panel. 8. On Quad Cab models, remove the two push-pin fasteners (1 and 4) that secure the rear cab trim panel (3) to the rear cab back panel and remove the trim panel. INSTALLATION 1. On Quad Cab models, position the rear cab trim panel (3) onto the rear cab back panel (2) and install the two push-pin fasteners (1 and 4). 2. On Quad Cab models, install the lower C-pillar trim panels. 3. On Quad Cab models, install the center seat belt trim bezel. 4. On Quad Cab models, install the child seat tether straps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7288 5. On Regular cab models, position the rear cab trim panel (1) onto the rear cab back panel (2) and install the utility hook (3) or the storage bin latch (4) (depending on application). 6. On Regular cab models, install the lower B-pillar trim panels. 7. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 N.m (55 in.lbs.). Rear Door Scuff Plate REAR DOOR SILL TRIM COVER REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the sill trim panel (1) from the retainer clips in the rear door sill (2) and remove the trim panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7289 INSTALLATION 1. Position the sill trim panel (1) onto the rear door sill (2). 2. Engage the retaining tabs that secure the sill trim panel to the rear door sill. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Service and Repair Utility Storage Compartment Latch: Service and Repair UNDER SEAT STORAGE BIN LATCH REMOVAL 1. Open the under seat storage bin. 2. Remove the two screws and remove the latch assembly. INSTALLATION 1. Install the latch assembly and install the screws. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove the exterior door handle (1). 2. Remove the clip (3) that secures the lock cylinder lever (5) and the electric lock switch (4), if equipped, to the door lock cylinder (6). 3. Remove the screw (2) that secures the door lock cylinder to the exterior handle and remove the lock cylinder. INSTALLATION 1. Position the door lock cylinder (6) into the exterior door handle (1). 2. Install the screw (2) that secures the door lock cylinder to the exterior door handle. Tighten the screw securely. 3. Install the electric lock switch (4), if equipped, and the lock cylinder lever (5) to the door lock cylinder. 4. Install the clip (3) that secures the lock cylinder lever and the electric lock switch, if equipped, to the door lock cylinder. 5. Install the exterior door handle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Testing and Inspection > Page 7302 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7307 Module-Sentry Key Immobilizer (SKIM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7308 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7309 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7310 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Testing and Inspection Keyless Entry Transmitter Battery: Testing and Inspection NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Testing and Inspection > Page 7319 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation Power Door Lock Actuator: Description and Operation The lock mechanisms are actuated by a reversible electric motor mounted within each door. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door lock motors are controlled by the instrument cluster. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 7323 Power Door Lock Actuator: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7327 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7328 Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Switch-Window/Door Lock Driver C1 Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7329 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock Power Door Lock Switch: Testing and Inspection Switch-Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 7332 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 7333 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock Power Door Lock Switch: Service and Repair Switch-Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock > Page 7336 Power Door Lock Switch: Service and Repair Switch-Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations > Page 7341 Heated Mirror Relay: Description and Operation The heated mirror relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The heated mirror relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the outside rear view mirror heating grids. The heated mirror relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The heated mirror relay is located in the IPM in the engine compartment. The ISO-standard heated mirror relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the outside rear view mirror heating grids. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the outside rear view mirror heating grids. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The heated mirror relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the heated mirror relay include: - Terminal (30) receives fused battery current at all times. - Terminal (86) receives a ground through the defogger relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (85) receives fused battery current through an ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the heated outside rear view mirror grids through the heated mirror relay output circuit only when the heated mirror relay coil is energized. - Terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the heated mirror relay coil is de-energized. The heated mirror relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete heated mirror system wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations > Page 7342 Heated Mirror Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for heated mirror relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the heated mirror relay from the IPM. INSTALLATION 1. Position the heated mirror relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the heated mirror relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 7346 Power Mirror Switch: Service and Repair The power mirror switch is included with the window/lock switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes PAINT CODES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7352 Paint: Application and ID Paint Code Location PAINT CODE LOCATION (TYPICAL-ALL MODELS) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description BASECOAT/CLEARCOAT FINISH DESCRIPTION The original equipment paint finish is a multi step process that involves cleaning, applying electro de-position (E-coat), anti-chip primer, basecoat, and clearcoat steps. CAUTION: Do not use abrasive chemicals, abrasive compounds or harsh alkaline based cleaning solvents on the painted surfaces of a vehicle. Failure to follow this caution can result in damage to vehicle finish. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. A clear coat paint is then applied to protect the basecoat from ultraviolet light and to provide a durable high-gloss finish. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 7355 Paint: Description and Operation Paint Code - Description PAINT CODE DESCRIPTION Exterior vehicle body color(s) are identified on the Vehicle Certification Label, Refer to Information Labels or Paint. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The color names provided in the Paint and Trim Code Description chart are the same color names used on most repair product containers, Refer to Paint. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP DESCRIPTION If the painted metal surface of a vehicle becomes scratched or chipped, it should be touched-up as soon as possible to avoid corrosion. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Failure to follow this warning may result in possible personal injury or death. When repairing painted metal surfaces, for best results, use MOPAR(R) Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. STANDARD PROCEDURE PAINT TOUCH-UP 1. Scrape any loose paint and corrosion from inside the scratch or chip. WARNING: Avoid prolonged skin contact with petroleum or alcohol-based cleaning solvents. Failure to follow this warning can result in possible personal injury or death. 2. Clean affected area with MOPAR(R) Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, the clearcoat can be lightly finesse sanded (1500 grit) and polished with rubbing compound. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 7358 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING/BUFFING AND POLISHING DESCRIPTION CAUTION: - Do not remove more than 0.5 mils of clearcoat finish when sanding, hand buffing or polishing. Basecoat paint must retain clearcoat for durability. - If the finish has been finesse sanded in the past, it cannot be repeated. Failure to follow this caution can result in damage to vehicle finish. NOTE: Finesse sanding should only be performed by a trained automotive paint technician. Minor acid etching, orange peel, or smudging in a clearcoat or single-stage finish can be reduced with light finesse sanding, hand buffing and polishing. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine clearcoat or single-stage paint thickness before and after the repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair UPPER RADIATOR CROSSMEMBER REMOVAL 1. Remove the hood latch from the upper radiator crossmember (3) and position the latch out of the way. 2. Remove the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator crossmember. 3. Remove the four bolts (1 and 3) that secure the upper radiator crossmember (2) to the fender rails and remove the crossmember. INSTALLATION 1. Position and align the upper radiator crossmember (2) to the fender rails. 2. Install the four bolts (1 and 3) that secure the upper radiator crossmember to the fender rails. Tighten the bolts to 28 N.m (21 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Page 7362 3. Install the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator cross-member (3). Tighten the bolts to 8 N.m (75 in.lbs.). 4. Install the hood latch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 7367 Heated Mirror Relay: Description and Operation The heated mirror relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The heated mirror relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the outside rear view mirror heating grids. The heated mirror relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The heated mirror relay is located in the IPM in the engine compartment. The ISO-standard heated mirror relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the outside rear view mirror heating grids. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the outside rear view mirror heating grids. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The heated mirror relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the heated mirror relay include: - Terminal (30) receives fused battery current at all times. - Terminal (86) receives a ground through the defogger relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (85) receives fused battery current through an ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the heated outside rear view mirror grids through the heated mirror relay output circuit only when the heated mirror relay coil is energized. - Terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the heated mirror relay coil is de-energized. The heated mirror relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete heated mirror system wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 7368 Heated Mirror Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for heated mirror relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the heated mirror relay from the IPM. INSTALLATION 1. Position the heated mirror relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the heated mirror relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7372 Module-Sentry Key Immobilizer (SKIM) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7373 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7374 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7375 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42°C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 7382 Power Seat Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 7383 Power Seat Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Module-Heated Seats Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7387 Seat Heater Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7388 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to testing for flashing LED diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to testing for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12 v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7389 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7403 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7404 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7405 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7406 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7412 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7413 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7414 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7415 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7424 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7425 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7426 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7427 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7433 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7434 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7435 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7436 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Motor-Sunroof Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 7440 Sunroof / Moonroof Motor: Testing and Inspection NOTE: If there is no sunroof movement when the "OPEN" or "CLOSED" button are pushed but the sunroof operates when the "VENT" button is pushed and held the sunroof motor/module is out of calibration. Complete the sunroof position calibration procedure prior to performing any sunroof diagnostics. The wire harness connectors for the sunroof motor/module are located above the vehicle headliner. Removal of the headliner may be necessary for access to the connector and proper diagnosis of the motor/module. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Verify that all other power accessories are in proper operating condition. If not, a common electrical problem may exist. 2. Disconnect the sunroof motor/module. Connect a test light between the harness connector pin 6 and a known good ground. The test light should illuminate brightly. If OK, go to Step 3. If not OK repair the ground circuit as necessary. 3. Connect a test light between the harness connector pin 8 and a known good ground. The test light should illuminate brightly. If OK, go to Step 4. If not OK repair the B+ circuit as necessary. 4. Turn the ignition key to the "RUN" position. Connect a test light between the harness connector pin 9 and a known good ground. The test light should illuminate brightly. If OK, go to Step 5. If not OK repair the Accessory Delay circuit as necessary. 5. Using an ohmmeter check the sunroof switch feed circuit for continuity between the sunroof motor/module and sunroof switch. Continuity should be present. If OK replace the inoperative motor/module. If not OK repair the sunroof switch feed circuit as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Procedures Sunroof / Moonroof Motor: Procedures Excessive Force Limitation (EFL) Calibration NOTE: Verify the battery is in good condition prior to performing this procedure. Do not leave the vehicle on a battery charger while performing this procedure. If the voltage at the sunroof motor/module drops below 11 volts or exceeds 15 volts at anytime while this procedure is being performed, the Excessive Force Limitation (EFL) function will not be properly calibrated. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for at least 1 second. 3. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of four sunroof closes. 4. Press the vent button on the power sunroof switch and release. The sunroof glass panel should move to the full vent position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the second sunroof closed position in a series of four sunroof closes. 5. Continue to move the sunroof glass to the "vent" then "closed" positions two more times so that the sunroof glass has moved to the closed position a total of four times starting with the first sunroof close in step 3. 6. Press the open position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full open position. 7. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of five sunroof closes. 8. Press the open position on the power sunroof switch and release. The sunroof glass panel should move to the full open position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. Continue to move the sunroof glass to the "open" then "closed" position four more times so that the sunroof glass has moved to the closed position a total of five times starting with the first sunroof close in step 7. Verify proper EFL calibration by placing a standard pencil at the front of the sunroof and then moving the sunroof to the full closed position. The sunroof should reverse direction upon contact without damage to the pencil. Sunroof Position Calibration Press the power sunroof switch (Open, Closed, and Vent). If no movement occurs when either the open switch or closed switch is pressed, but the system does move when the vent button is pressed and held, the system is not calibrated. Perform the following procedure to position calibrate the power sunroof system. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for atleast 1 second. 3. Press the close switch on the power sunroof switch and hold for a moment (at least 100ms) and release. The sunroof glass panel should continue travel to the full close position. If the sunroof glass panel does not return to the full close position, refer to the appropriate diagnostic information for full system diagnosis. 4. Verify proper system operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Procedures > Page 7443 Sunroof / Moonroof Motor: Removal and Replacement WARNING: THE EXCESSIVE FORCE LIMITATION (EFL) FEATURE MUST BE CALIBRATED ANY TIME A SUNROOF MOTOR/MODULE IS REPLACED WITH A NEW COMPONENT. FAILURE TO PERFORM THIS PROCEDURE COULD RESULT IN VEHICLE DAMAGE AND/OR PERSONAL INJURY. REMOVAL 1. Disconnect the battery negative cable. 2. Remove the vehicle headliner. 3. Remove the power sunroof motor/module electrical connector (2). 4. Remove the retaining screws (3) and remove the motor/module (1) from the vehicle. INSTALLATION 1. Position the power sunroof motor/module (1) in the vehicle. 2. Install the motor/module retaining screws (3). Tighten the screws to 4 N.m (35 in.lbs.). 3. Connect the motor/module electrical connector (2). 4. Connect the battery negative cable and move the sunroof through one open and close cycle to confirm proper system operation. 5. Install the vehicle headliner. 6. Perform the sunroof position calibration. 7. Perform the Excessive Force Limitation (EFL) calibration. 8. Verify proper operation of the power sunroof system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Switch-Sunroof Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 7447 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination push button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions or the vehicle Accessory Delay System is active. When one of the switch positions is pressed it sends battery current back to the motor/ module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 7448 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Head Rest: Service and Repair Headrest HEADREST REMOVAL 1. Raise the headrest. 2. Press the headrest release button and remove the headrest. INSTALLATION 1. Position the headrest. 2. Press the release button and install the headrest. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 7454 Head Rest: Service and Repair Headrest Sleeve HEADREST SLEEVE REMOVAL 1. Remove the headrest. 2. Grasp the sleeves and pull up and out of the seat back to remove. INSTALLATION 1. Position each headrest sleeve into correct seat back hole and press into place fully. 2. Install the headrest. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42°C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Page 7458 Power Seat Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Page 7459 Power Seat Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Power Seat Motor: Diagrams Motor-Lumbar Driver Motor-Lumbar-Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt-Driver Switch-Seat Driver Switch-Seat-Passenger (Quad Cab) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 7466 Switch-Seat Passenger (Standard Cab) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 7467 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 7468 Power Seat Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If not OK, replace the inoperative power seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 7469 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Diagrams Seat Cushion: Diagrams Heater - Seat Cushion Driver Heated - Seat Cushion-Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Connector Views Seat Heater: Connector Views C316 (Heated Seats) C322 (Heated Seats) C322 (Heated Seats) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Connector Views > Page 7477 C323 (Heated Seats) C323 (Heated Seats) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats Seat Heater: Description and Operation Heated Seats WARNING: THE FRONT PASSENGER SEAT ASSEMBLY CONTAINS CRITICAL COMPONENTS THAT AFFECT THE FRONT PASSENGER AIRBAG DEPLOYMENT. CORRECTLY FUNCTIONING FRONT PASSENGER SEAT COMPONENTS ARE CRITICAL FOR THE OCCUPANT CLASSIFICATION SYSTEM (OCS) TO PROPERLY CLASSIFY THE FRONT PASSENGER AND CALCULATE THE PROPER AIRBAG DEPLOYMENT. UNAPPROVED MODIFICATIONS OR SERVICE PROCEDURES TO THE FRONT PASSENGER SEAT ASSEMBLY, ITS RELATED COMPONENTS, OR TRIM COVER MAY INADVERTENTLY CHANGE THE AIRBAG DEPLOYMENT IN CASE OF A FRONTAL CRASH. THIS COULD RESULT IN DEATH OR SERIOUS INJURY TO THE FRONT SEAT PASSENGER IF THE VEHICLE IS INVOLVED IN AN ACCIDENT. The following requirements must be strictly adhered to: - Do not modify the front passenger seat assembly or components in any way. - Do not modify the front seat center console or center position seat in any way. - Do not use prior or future model year seat trim covers not designated for the specific model being repaired. always use the correct seat trim cover specified for the vehicle. - Do not replace the seat trim cover with an aftermarket trim cover. - Do not add a secondary trim cover other than those approved by daimlerchrysler mopar. - At no time should any supplemental restraint system (srs) component or srs related component or fastener be modified or replaced with any part except those which are approved by daimlerchrysler/mopar. Vehicles with the heated seat option can be visually identified by the two heated seat switches located in the center stack of the instrument panel. The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system for this vehicle includes the following major components, which are described in further detail later : - Heated Seat Switches - Two heated seat switches are used per vehicle. One switch is used for each front seat. The switches are mounted in the instrument panel, below the radio. Each switch also includes two Light-Emitting Diode (LED) indicator lamps and an incandescent back lighting bulb. - Heated Seat Module - This module contains the solid state electronic control and diagnostic logic circuitry for the heated seat system. One heated seat module is used per vehicle and is mounted under the drivers front seat cushion. - Heated Seat Elements - Four heated seat elements are used per vehicle. One element is used for each front seat back and one element and sensor assembly is used for each front seat cushion. The heating elements are integral to the individual front seat and seat back cushions and cannot be removed once installed at the factory. Replacement seat heating elements are available, without having to replace the entire seat cushion or trim cover. - Heated Seat Sensors - Two heated seat sensors are used per vehicle. One heated seat temperature sensor is used for each front seat cushion. The sensors are integral to the individual front seat cushion heating elements and cannot be removed once installed at the factory. Replacement seat heating elements with the sensors are available, without having to replace the entire seat cushion or trim cover. The heated seat module receives fused battery current through the Integrated Power Module. The heated seat switches receive battery current from the Cab Compartment Node (CCN) only when the ignition switch is in the On position and the engine is running. The heated seat module shares a common ground circuit with each of the heated seat elements. The heated seat system will control the surface temperature of the seat cushion to within the designed temperature set points of the system. The heated seat system will also automatically turn off whenever the ignition switch is turned to any position except On, or if the engine quits running. If the ignition switch is turned to the Off position or if the engine quits running while a heated seat is ON, the heated seat will remain Off after the engine is restarted until a heated seat switch is depressed again. This helps prevent the vehicles battery from being drained by the heated seat system. The heated seat module monitors inputs from the heated seat sensors and the heated seat switches. In response to these inputs the heated seat module uses its internal programming to control 12v to the heated seat elements in both front seats and to control the heated seat LED indicator lamps located in both of the heated seat switches. The heated seat module is also programmed to provide self-diagnostics, if a problem with the heated seat system is detected. If the module detects certain failures within the heated seat system, it will provide a visual indication of the failure by flashing the indicator lamps in the appropriate heated seat switch. The heated seat module will automatically turn off the heated seat elements if it detects a short or open in the heated seat element circuit or a heated seat sensor value that is out of range. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats > Page 7480 Seat Heater: Description and Operation Heated Seat Element Vehicles equipped with the optional heated seat system have two sets of electrically operated heating element grids located in each front seat, one set for the seat cushion and the other set for the seat back. Each of the heated seat element grids consists of a single length of resistor wire that is routed in a zigzag pattern and captured between a covering and the adhesive foam rubber backing. Short pigtail wires with connectors are soldered to each end of each resistor wire element grid, which connect all of the element grids to the heated seat module through the seat wire harness. One temperature sensor is used for each front seat, and it is located in the center insert area of the seat cushion element. The heated seat sensors and their pigtail wires are also captured between a covering and the adhesive foam rubber backing. The heated seat sensors are Negative Thermal Coefficient (NTC) thermistors. The sensors for both front seats receive a voltage feed from a single output of the heated seat module, but the module receives individual sensor inputs from the driver side and passenger side sensors. The heated seat elements and sensors should not be repaired. If damaged or faulty, the heated seat element assembly must be replaced. One end of the heated seat element resistor wire is connected to ground at all times through a splice in the heated seat module ground circuit. Battery current is directed to the other end of the heated seat element resistor wire by the energized N-channel Field Effect Transistor (N-FET) located within the heated seat module. The heated seat module will energize the N-FET only when the heated seat switch is in the Low or High position and the heated seat sensor indicates that the seat cushion surface temperature is below the selected (Low or High) temperature set point. As electrical current passes through the heating element grid, the resistance of the wire used in the element disperses some of that electrical current in the form of heat. The heat produced by the heated seat element grid then radiates through the seat trim cover, warming its occupant. The resistance of the heated seat sensor increases and decreases as the surface temperature of the seat cushion cover changes. The heated seat module supplies each sensor with a 5v voltage feed, then uses the sensor resistance to determine when the heated seat element grids need to be cycled on or off in order to maintain the selected temperature set point. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element Seat Heater: Testing and Inspection Heated Seat Element The heated seat module will self-diagnose shorted or open heated seat element circuits and sensor circuits. To manually check the heated seat element, proceed as follows. The wire harness connectors for the seat cushion and seat back heating elements and sensor are located on the right side of the seat, near the edge of the seat cushion frame. The proper connector can be identified by the foam wrapping. NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Position the appropriate seat in the full forward position. 2. Make certain the ignition switch is in the OFF position. 3. Disconnect the heated seat element connector which requires testing. Check for continuity between the two heated seat element circuit cavities while moving the appropriate seat cushion. the appropriate wiring information for the location of complete heated seat system wiring diagrams. There should be continuity. If OK, the elements within the seat assembly test OK, go to Step 4. If not OK, replace the inoperative seat heating element. 4. Test the seat wire harness between the heated seat module connector and the appropriate heated seat wire harness connector for shorted or open circuits. If OK, element is OK, proceed with testing the heated seat sensor and module. If not OK, repair the shorted or open seat wire harness as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element > Page 7483 Seat Heater: Testing and Inspection Heated Seat System The heated seat system is capable of performing some self-diagnostics. The following table depicts the various monitored conditions which will be reported to the vehicle operator or technician by flashing the individual heated seat switch Light Emitting Diode (LED) indicator lamps. Refer to the HEATED SEAT SYSTEM SELF-DIAGNOSIS table for condition identification. The driver heated seat switch indicator lamps will flash if a malfunction occurs in the driver heated seat, and the passenger heated seat switch indicator lamps will flash for a passenger heated seat malfunction. If a monitored heated seat system malfunction occurs, the switch indicator lamps will flash at a pulse rate of about one-half second on, followed by about one-half second off for a duration of about one minute after the switch for the inoperative heated seat is depressed in either the Low or High direction. This process will repeat every time the inoperative heated seat switch is actuated until the problem has been corrected. Heated Seat System Self-diagnosis Diagnostic logic is built into the heated seat module to help locate the problem by the most efficient means possible. Anytime a problem is suspected, locate the diagnosis and testing procedure for the component in question and follow the steps until the specific problem is located and resolved. Once the problem is thought to be corrected, verify correct system operation. If the heated seat system is functioning correctly return the vehicle to service. If a problem could not be verified such as not finding anything wrong when following the diagnostic procedure, this is a good indication that an INTERMITTENT problem may be present. You must then attempt to find the intermittent problem, such as moving the heating element within the seat while testing continuity or wiggling the wire harness's/ electrical connectors under the seat while testing continuity. Always, eliminate all other potential problems before attempting to replace the heated seat module. PRELIMINARY TEST Refer to Wiring for the location of complete heated seat system wiring diagrams. Before testing the individual components in the heated seat system, perform the following preliminary checks: WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - If the heated seat switch back lighting and the cluster illumination lamps do not illuminate with the headlamps or park lamps turned On, refer to the Instrument Cluster for the location of cluster illumination lamp diagnosis and testing procedures. If the heated seat switch back lighting does not illuminate, but the cluster illumination lamps do illuminate with the headlamps or park lamps turned On. - If a single LED indicator lamp for one heated seat switch does not operate and the heated seat elements do heat, refer to testing for the heated seat switch diagnosis and testing procedures. - If both LED indicator lamps for a heated seat switch operate, but the heated seat elements do not heat. - If the indicator lamp on either heated seat switch remains illuminated after the heated seat has been turned Off. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 7484 Seat Heater: Service and Repair REMOVAL CAUTION: Do not remove the heating element from the seat or seat back cushion. The original element is permanently attached to the seat cushions and cannot be removed without damaging the cushion. The replacement heating element is designed to be applied directly over the original seat heating element. 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate seat cushion or seat back trim cover. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors. 4. Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. INSTALLATION 1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick directly over the original heating element (1). CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. 2. Connect the new heating element electrical connectors. 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion or seat back trim cover. Make certain the seat wire harness is correctly routed through the seat and seat back. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams Module-Heated Seats Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7488 Seat Heater Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7489 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to testing for flashing LED diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to testing for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12 v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7490 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if inoperative. The heated seat temperature sensor is part of the heated seat cushion element and must be replaced as an assembly. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation > Page 7494 Seat Heater Sensor: Testing and Inspection NOTE: Any resistance values (OHMS) given in the following text are supplied using the automatic range generated by a FLUKE ■ automotive meter. If another type of measuring device is used, the values generated may not be the same as the results shown here, or may have to be converted to the range used here. 1. Position the driver seat in the full rearward position. 2. Unclip the heated seat module from the bottom of the drivers seat cushion pan. 3. Back-probe the heated seat module wire harness connector, do not disconnect. Check cavity (#7 for passenger, #8 for driver seat) for a range in voltage from approx. 1.72 - 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to the appropriate wiring information for the complete heated seat system wiring diagrams. If 5 volts is not being supplied to the sensor from the module, replace the heated seat module. 4. Test the seat wire harness between the heated seat module connector and the heated seat wire harness connector for shorted or open circuits. If OK, refer to testing for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7498 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7499 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7500 Seat Heater Switch: Diagrams Switch-Heated Seat Driver Switch-Heated Seat-Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7501 Seat Heater Switch: Description and Operation The momentary, bidirectional rocker-type heated seat switch (1) provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps (2), which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time, the heated seat module interprets the second input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indicate heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7502 Seat Heater Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, Refer to electrical/instrument cluster - diagnosis and testing. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, Refer to electrical/electronic control modules/memory heated seat/mirror module - diagnosis and testing. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required. Heated Seat Switch Continuity 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, Refer to electrical/electronic control modules/memory heated seat/mirror module - diagnosis and testing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7503 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag or instrument panel service. 3. Remove the center bezel from the instrument panel. 4. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 5. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 6. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the battery negative cable. 5. Verify vehicle and system operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation Seat Track: Description and Operation The eight-way power seat option includes a power seat track assembly (1) located under each front seat. The power seat track assembly replaces the standard manually operated seat tracks. The lower half of the power seat track is secured at the front with two bolts to the floor panel seat cross member, and at the rear with two bolts to the floor panel. Four nuts secure the bottom of the seat cushion frame to the upper half of the power seat track unit. The power seat track assembly cannot be repaired, and is serviced only as a complete assembly. If any component in this assembly is inoperative or damaged, the entire power seat track must be replaced. The power seat track unit includes three reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. The third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 7507 Seat Track: Testing and Inspection For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat track fails to operate in only one direction, move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit. If the power seat track still fails to operate in only one direction, refer to testing for power seat switch diagnosis. If the power seat track fails to operate in more than one direction, proceed as follows: 1. Check the power seat fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the circuit as necessary and replace the inoperative fuse. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the integrated power module as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch. If the switch tests OK, check the wire harness between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the inoperative power seat track (adjuster) assembly. If the circuits are not OK, repair the wire harness as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 7508 Seat Track: Service and Repair REMOVAL 1. Remove the appropriate seat from the vehicle. 2. Remove the power seat switch from the seat. 3. Remove four seat track mounting nuts from cushion pan. 4. Disconnect the power seat electrical connectors and remove the seat track from the seat cushion. 5. Remove the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). INSTALLATION 1. Install the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). 2. Position the seat track and install the retaining nuts on the seat cushion pan studs. Torque the bolts to 25 N.m. 3. Route and connect the power seat electrical connectors on the seat track and cushion pan. 4. Install the power seat switch on the seat. 5. Install the seat in the vehicle. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Testing and Inspection > Page 7513 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations > Page 7517 Door Position Switch: Description and Operation Vehicles that are equipped with the optional Vehicle Theft Security System (VTSS) have a door cylinder lock switch (1) secured to the back of the key lock cylinder inside the driver side front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between ground and the cylinder lock switch mux circuit input to the ElectroMechanical Instrument Cluster (EMIC) through a pigtail wire (2) connected to the left front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contains two internal resistors. One resistor value is used for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a circuit between ground and the cylinder lock switch mux circuit through one of two internal resistors for the ElectroMechanical Instrument Cluster (EMIC) when the driver side front door key lock cylinder is in the Lock, or Unlock positions. The EMIC reads the switch status through an internal pull-up, then uses this information as an input for the Vehicle Theft Security System (VTSS) operation, as well as for control of a central locking feature for the power lock system. The door cylinder lock switch and circuit may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC or its responses to the cylinder lock switch inputs. The most reliable, efficient, and accurate means to diagnose the door cylinder lock switch, the EMIC, and both the hard wired and electronic message inputs and outputs affected by the door cylinder lock switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 7521 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 7522 Starter-Adjustable Pedals (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 7523 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7527 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7528 Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Switch-Window/Door Lock Driver C1 Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7529 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock Power Door Lock Switch: Testing and Inspection Switch-Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 7532 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 7533 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock Power Door Lock Switch: Service and Repair Switch-Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock > Page 7536 Power Door Lock Switch: Service and Repair Switch-Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 7540 Power Mirror Switch: Service and Repair The power mirror switch is included with the window/lock switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt-Driver Switch-Seat Driver Switch-Seat-Passenger (Quad Cab) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 7544 Switch-Seat Passenger (Standard Cab) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 7545 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 7546 Power Seat Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If not OK, replace the inoperative power seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 7547 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if inoperative. The heated seat temperature sensor is part of the heated seat cushion element and must be replaced as an assembly. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 7551 Seat Heater Sensor: Testing and Inspection NOTE: Any resistance values (OHMS) given in the following text are supplied using the automatic range generated by a FLUKE ■ automotive meter. If another type of measuring device is used, the values generated may not be the same as the results shown here, or may have to be converted to the range used here. 1. Position the driver seat in the full rearward position. 2. Unclip the heated seat module from the bottom of the drivers seat cushion pan. 3. Back-probe the heated seat module wire harness connector, do not disconnect. Check cavity (#7 for passenger, #8 for driver seat) for a range in voltage from approx. 1.72 - 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to the appropriate wiring information for the complete heated seat system wiring diagrams. If 5 volts is not being supplied to the sensor from the module, replace the heated seat module. 4. Test the seat wire harness between the heated seat module connector and the heated seat wire harness connector for shorted or open circuits. If OK, refer to testing for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Rear Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 7555 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 7556 Center Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 7557 Seat Heater Switch: Diagrams Switch-Heated Seat Driver Switch-Heated Seat-Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 7558 Seat Heater Switch: Description and Operation The momentary, bidirectional rocker-type heated seat switch (1) provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps (2), which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time, the heated seat module interprets the second input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indicate heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 7559 Seat Heater Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, Refer to electrical/instrument cluster - diagnosis and testing. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, Refer to electrical/electronic control modules/memory heated seat/mirror module - diagnosis and testing. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required. Heated Seat Switch Continuity 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, Refer to electrical/electronic control modules/memory heated seat/mirror module - diagnosis and testing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 7560 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag or instrument panel service. 3. Remove the center bezel from the instrument panel. 4. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 5. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 6. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the battery negative cable. 5. Verify vehicle and system operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Switch-Sunroof Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 7564 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination push button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions or the vehicle Accessory Delay System is active. When one of the switch positions is pressed it sends battery current back to the motor/ module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 7565 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations NVH/SOUND DEADENER LOCATIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7569 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7570 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7571 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair FRONT AIR DAM REMOVAL 1. Remove the two outboard screws. 2. Remove the three middle screws and remove the air dam. INSTALLATION 1. Position the air dam onto the bumper and seat the carrot type fasteners fully. 2. Starting at the center screw install the three middle screws. 3. Install the two outboard screws. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Cover > Component Information > Service and Repair Tailgate Cover: Service and Repair COVER REMOVAL 1. Open the tailgate (1) and remove the tailgate liner, if equipped. 2. Remove the ten bolts (2) that secure the tailgate cover (3) to the inside of the tailgate and remove the cover. INSTALLATION 1. Position the tailgate cover (3) onto the inside of the tailgate (1). 2. Install the ten bolts (2) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 3. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair Tailgate Hinge: Service and Repair HINGE REMOVAL 1. Remove the tailgate. 2. If required, remove the bushing (3) from each tailgate hinge (1). 3. Remove the two bolts (4) that secure each tailgate hinge (1) to the cargo box (2) and remove the hinge(s) as necessary. INSTALLATION 1. Position the tailgate hinge(s) onto the cargo box (2) as necessary. 2. Install the two bolts (4) that secure each tailgate hinge to the cargo box. Tighten the bolts to 34 N.m (25 ft.lbs.). 3. If removed, install the bushing (3) onto each tailgate hinge. 4. Install the tailgate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch LATCH REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the actuator rod (3) at the control (2) for the latch (1) being serviced. 4. Disconnect the actuator rod from the control. 5. Remove the two bolts (7 and 8) that secure the latch (5) to the tailgate (4) and position the tailgate check cable (6) out of the way. 6. Remove the latch and actuator rod from the tailgate as an assembly. 7. If required, remove the actuator rod from the latch. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 7587 1. If removed, install the actuator rod onto the latch (5) being serviced. 2. Install the latch and actuator rod into the tailgate (4) as an assembly. 3. Position the tailgate check cable (6) onto the tailgate and install the two bolts (7 and 8) that secure the latch and the check cable to the tailgate. Tighten the bolts to 23 N.m (17 ft.lbs.). 4. Locate the actuator rod (3) to the control (2) using the reference mark made during the removal procedure and connect the rod to the control. 5. Position the tailgate cover (4) onto the inside of the tailgate. 6. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 7. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 7588 Tailgate Latch: Service and Repair Tailgate Latch Striker LATCH STRIKER REMOVAL 1. Open the tailgate and using a grease pencil or equivalent, mark the location of the tailgate striker (1) being serviced. 2. Remove the striker from the cargo box (2). INSTALLATION 1. Position the striker (1) onto the cargo box (2) using the reference mark made during the removal procedure. 2. Tighten the striker to 34 N.m (25 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair RELEASE HANDLE REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the location of the actuator rods (3) at the control (2). 4. Disconnect the actuator rods from the control. 5. Remove the two nuts (3) that secure the release handle (1) and the control (2) to the tailgate (4). 6. Remove the control and the release handle from the tailgate. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 7592 1. Position the release handle and the control onto the tailgate. 2. Install the two nuts that secure the release handle and control to the tailgate. Tighten the nuts to 7 N.m (60 in.lbs.). 3. Locate the actuator rods (3) to the control (2) using the reference marks made during the removal procedure and connect the rods to the control. 4. Position the tailgate cover (4) onto the inside of the tailgate. 5. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 6. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair Tailgate Shock / Support: Service and Repair CABLE-CHECK REMOVAL 1. Open the tailgate and locate the tailgate check cable (3) on the left and right of the cargo box below the tailgate striker (1) as necessary. 2. Pry the cable lock tab(s) (4) outward using a screwdriver or flat bladed tool (2) and remove the tailgate check cable(s) from the cargo box. 3. Remove the bolt (1) that secures the tailgate check cable (2) to the left and right side of the tailgate (3) as necessary. 4. Remove the tailgate check cable(s) from the tailgate. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Page 7596 1. Position the tailgate check cable (2) onto the left and right side of the tailgate (3) as necessary. 2. Install the bolt (1) that secures the small end of the tailgate check cable(s) to the tailgate. Tighten the bolt(s) to 23 N.m (17 ft.lbs.). 3. Position the tailgate check cable (3) to the left and right side of the cargo box below the tailgate striker (1) as necessary. 4. Install the large end of the tailgate check cable(s) onto the cargo box. Make sure that the cable lock tab(s) (4) fully engage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK ASSEMBLY REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Page 7600 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 N.m (50 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Truck Bed: Service and Repair Cargo Box CARGO BOX NOTE: Long cargo box shown in illustration. Short cargo box similar. REMOVAL 1. Remove the screws (1) that secure the fuel filler (2) to the cargo box (3). 2. Remove the fuel filler from the cargo box and position it out of the way. 3. If necessary, remove the fuel filler door from the cargo box. 4. Disconnect the tail lamp wire harness from the underbody wire harness. 5. If necessary, remove the tail lamp units and wire harness from the cargo box. 6. If necessary, remove the tailgate. 7. If necessary, remove the rear bumper. 8. Remove the bolts (3) that secure the cargo box (1) to the frame (2) (six short box, eight long box) and remove the cargo box. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 7605 1. Position the cargo box (1) onto the frame (2) and loosely install the bolts (3) (six short box, eight long box). 2. Align the cargo box to the cab and tighten the bolts to 108 N.m (80 ft.lbs.). 3. If removed, install tail lamp units and wire harness onto the cargo box. 4. Connect the tail lamp wire harness to the underbody wire harness. 5. If removed, install the tailgate. 6. If removed, install the rear bumper. 7. If removed, install the fuel filler door. 8. Position the fuel filler (2) to the cargo box (3). 9. Install the screws (1) that secure the fuel filler to the cargo box. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 7606 Truck Bed: Service and Repair Cargo Box-Tie Down CARGO BOX-TIE DOWN REMOVAL 1. Remove the two bolts (1) that secure each cargo box tie down (2) to the cargo bed and remove the cleats as necessary. INSTALLATION 1. Position the cargo box tie downs (2) to the cargo box as necessary. 2. Install the two bolts (1) that secure each cargo box tie down to the cargo box. Tighten the bolts to 34 N.m (25 ft.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7617 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer A-PILLAR WEATHERSTRIP RETAINER REMOVAL 1. Remove the drip rail weatherstrip retainer (1). 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7618 Front Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7619 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7620 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7621 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7622 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7623 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7624 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7625 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer DRIP RAIL WEATHERSTRIP RETAINER REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7630 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7631 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7632 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7633 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7634 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7635 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7636 2. Install the door trim panel (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7641 Rear Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7642 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7643 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7644 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7645 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7646 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7647 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7652 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7653 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7654 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7655 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7656 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7657 2. Install the door trim panel (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Cruise Control Servo: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 7662 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control-Left (ETC) Switch-Speed Control-Left (Except ETC) Switch-Speed Control-Right (ETC) Switch-Speed Control-Right (Except ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 7666 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 7667 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control-Left (ETC) Switch-Speed Control-Left (Except ETC) Switch-Speed Control-Right (ETC) Switch-Speed Control-Right (Except ETC) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 7672 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 7673 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. On vehicles equipped with a gasoline engine, the ABS indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. On vehicles equipped with a diesel engine, the ABS indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ABS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 Audible Warning Device: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 Chime System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7703 Audible Warning Device: Description and Operation A chime warning system is standard factory-installed equipment. The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the electronic circuit board inside of the ElectroMechanical Instrument Cluster (EMIC) (1) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The EMIC also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN. The electromechanical transducer generates beep tones and chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based EMIC utilizes electronic chime request messages received from other modules in the vehicle over the Programmable Communications Interface (PCI) data bus network along with hard wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the EMIC allow it to control the audible outputs that are produced through its on-board transducer and relay. The EMIC is capable of producing the following audible outputs: - Slow Rate Repetitive Click - Repeated "click" tones that are issued at a slow rate of about 50 clicks per minute. - Fast Rate Repetitive Click - Repeated "click" tones that are issued at a fast rate of more than about 100 clicks per minute. - Fixed Duration Beep - A short, sharp, single tactile "beep" tone. - Single Chime Tone - A single "chime" tone. - Slow Rate Repetitive Chime - Repeated "chime" tones that are issued at a slow rate of about 50 chimes per minute. - Fast Rate Repetitive Chime - Repeated "chime" tones that are issued at a fast rate of about 180 chimes per minute. Hard wired circuitry connects the EMIC and the various chime warning system switch and sensor inputs to their modules and to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the EMIC through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7704 The EMIC chime warning system circuits and components cannot be adjusted or repaired. If the EMIC circuitry, the on-board transducer or the relay are damaged or faulty, the EMIC unit must be replaced. The chime warning system operates on battery voltage received through the Ignition-Off Draw (IOD) fuse in the Power Distribution Center (PDC) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system also monitors the ignition switch position so that some chime features are functional only with the ignition switch in the On position, while others are functional regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator or occupants under the following conditions: - Airbag Indicator Warning - The ElectroMechanical Instrument Cluster (EMIC) transducer will generate one short chime when the ignition switch is in the On position, and an electronic message is received over the Programmable Communications Interface (PCI) data bus from the Airbag Control Module (ACM) requesting "Airbag" indicator illumination. This warning will only occur following completion of the "Airbag" indicator bulb test, and will only occur once during any ignition cycle. - Compass Mini-Trip Computer Global Reset - The EMIC transducer will generate one short chime when the ignition switch is in the On position, and an electronic message is received over the PCI data bus from the optional Compass Mini-Trip Computer (CMTC) requesting that the CMTC average fuel economy, trip odometer and distance to empty data be reset. The CMTC monitors hard wired inputs from the U.S./Metric and Reset button switches to determine the proper reset messages to send to the EMIC. Door Ajar Indicator Warning - The EMIC transducer will generate one short chime when the ignition switch is in the On position, a hard wired input is received indicating that the status of any door ajar switch has changed, and an electronic message is received over the PCI data bus indicating that the vehicle is moving. - Engine Coolant Temperature High Warning (Diesel Engine Only) - The EMIC transducer will generate a single chime tone when the "Check Gauges" indicator is illuminated for a high or critical engine coolant temperature condition. The instrument cluster uses engine coolant temperature message inputs received from the diesel Engine Control Module (ECM) over the PCI data bus to illuminate the "Check Gauges" indicator for a coolant temperature high condition. - Fasten Seat Belt Indicator Warning - The EMIC transducer will generate repetitive chimes at a slow rate to announce that a hard wired input from the seat belt switch indicates that the driver side front seat belt is not fastened with the ignition switch in the On position. The chime warning system also supports the enhanced seatbelt reminder (beltminder) when this feature is enabled. - Head/Park Lamps-On Warning - The EMIC transducer will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the headlamp switch, and the ignition switch indicate that the exterior lamps are turned On with the driver side front door opened and the ignition switch in the Off position. The chimes will continue to sound until the exterior lamps are turned Off, the driver side front door is closed, or the ignition switch is turned to the On position, or the battery saver (load shed) time-out expires, whichever occurs first. - Key-In-Ignition Warning - The EMIC transducer will generate repetitive chimes at a fast rate to announce that the hard wired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition switch circuitry of the ignition switch indicate that the key is in the ignition lock cylinder with the driver side front door open and the ignition switch in the Off position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the On position, whichever occurs first. - Low Fuel Indicator Warning - The EMIC transducer will generate one short chime tone when the "Low Fuel" indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Low Oil Pressure Warning (Diesel Engine Only) - The EMIC transducer will generate repetitive chimes at a fast rate when the "Check Gauges" indicator is illuminated for a low oil pressure condition. The instrument cluster uses engine speed and oil pressure message inputs received from the diesel Engine Control Module (ECM) over the PCI data bus indicating that the engine is running and that the oil pressure is low to illuminate the "Check Gauges" indicator. The chimes will continue to sound for five seconds, until the engine oil pressure message indicates that the oil pressure is not low, or until the engine speed message indicates that the engine is not running, whichever occurs first. This chime will only occur once during any ignition cycle. - Low Wash Indicator Warning - The EMIC transducer will generate one short chime when the "Low Washer Fluid" indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Overspeed Warning - The EMIC transducer will generate repetitive chimes at a slow rate to indicate that the vehicle speed is over a pre-programmed speed value. The EMIC monitors electronic vehicle speed messages received over the PCI data bus. This feature is only enabled on an EMIC that has been programmed with a Middle East Gulf Coast Country (GCC) country code. - Park Brake Reminder - The EMIC transducer will generate ten repetitive chimes at a slow rate to announce that the hard wired input from the park brake switch and a vehicle speed message input received over the PCI data bus indicate that the park brake is applied and the vehicle is moving. This chime will repeat each time the input conditions are met. - Sentry Key "Customer Learn" Mode Announcement - The EMIC transducer will generate one short chime to confirm that an electronic "Customer Learn" mode message has been received over the PCI data bus to indicate the Sentry Key Immobilizer Module (SKIM) is prepared for programming additional sentry key transponders. This chime feature is only active on vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), and sold in markets where "Customer Learn" programming is an allowed feature. - Trans Overtemp Indicator Warning (Automatic Transmission Only) - The EMIC transducer will generate repetitive chimes at a slow rate when the "Trans Temp" indicator is illuminated by the instrument cluster circuitry for a high or critical transmission fluid temperature condition. This chime will repeat each time the trans overtemp indicator is cycled from Off to On. - Turn Signal/Hazard Warning Flasher Emulation - The EMIC relay will generate repetitive clicks at a slow rate to emulate an electromechanical flasher when the turn signal or hazard warning system are operating. The EMIC relay will generate repetitive clicks at a fast rate to indicate that the right or left turn signal are operating with one or more bulbs inoperative. In either case, the clicks will continue until the turn signal and hazard warning systems are turned off. - Turn Signal On Warning - The EMIC transducer will generate repetitive chimes at a slow rate to indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers for this feature. The chime will continue until Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7705 the turn signal input becomes inactive or until the vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Indicator Announcement - The EMIC transducer will generate one short chime each time the "Check Gauges" indicator is illuminated by the instrument cluster circuitry. The "Check Gauges" indicator may be illuminated when any critical engine or transmission systems are operating outside of their normal parameters. The instrument cluster monitors electronic messages received over the PCI data bus to determine when to illuminate the "Check Gauges" indicator. The EMIC provides chime service for all available features in the chime warning system. The EMIC relies upon its internal programming, numerous hard wired inputs, and electronic message inputs received from other modules over the PCI data bus network to provide the chime warning system features. The internal programming of the EMIC determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hard wired chime warning system inputs to the EMIC may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messages received by the EMIC from other modules for control of the chime warning system. The most reliable, efficient and accurate means to diagnose the EMIC, the PCI data bus, or the electronic message inputs used for the chime warning system requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation Check Gauges Lamp: Description and Operation A check gauges indicator is standard equipment on all instrument clusters. On vehicles equipped with a gasoline engine, the check gauges indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. On vehicles equipped with a diesel engine, the check gauges indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The check gauges indicator consists of a stencil-like cutout of the words "CHECK GAGES" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "CHECK GAGES" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The check gauges indicator is serviced as a unit with the instrument cluster. The check gauges indicator gives an indication to the vehicle operator when certain instrument cluster gauge readings reflect a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The check gauges indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the check gauges indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the check gauges indicator is illuminated for about two seconds as a bulb test. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature of a gasoline engine is about 122° C (252° F) or higher, or of a diesel engine is about 112° C (233° F) or higher, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine coolant temperature of a gasoline engine is below about 122° C (252° F), or of a diesel engine is below about 112° C (233° F), or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is about 41 kPa (6 psi) or lower, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the indicator on in response to an engine oil pressure low message if the engine speed is greater than zero. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is less than about 9.0 volts (charge fail condition) or that the battery temperature sensor input is an open circuit, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is greater than about 9.5 volts (but less than about 15.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - System Voltage High Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is greater than about 15.5 volts, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the check gauges indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. On vehicles with a diesel engine, the ECM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. For proper diagnosis of the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the check gauges indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7717 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7718 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7722 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 8w-41-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7736 Cigarette Lighter: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7737 Cigarette Lighter: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation MODULE-COMPASS TEMPERATURE The compass mini-trip computer is located in the overhead console (7) on models equipped with this option. The compass mini-trip computer includes a Vacuum-Fluorescent Display (VFD) (6), an Electronic Overhead Module (EOM) and push button function switches (1, 2, 4 and 5). The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communications Interface (PCI) data bus. The PCI data bus allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer supports and/or controls, include the following display options: - Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned off. The ambient temperature sensor is hard wired to the Front Control Module (FCM). Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through PCI data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a scan tool and the proper Diagnostic Procedures Information are recommended for further testing of the EOM and the PCI data bus. The EOM cannot be repaired, and is available for service only as a unit. This unit includes the push button switches, the Universal Garage Door Transmitter and the plastic module and display lens. If any of these components is inoperative or damaged, the complete EOM must be replaced. COMPASS While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized. TEMPERATURE The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 7741 the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position again, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the FCM, which sends temperature over the PCI data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display min and max temperatures of -40° C (-40° F) and 54° C (130° F). The compass mini-trip computer only operates with the ignition switch in the On position. When the ignition switch is turned to the On position, all of the segments in the compass mini-trip computer Vacuum-Fluorescent Display (VFD) will be turned off for one second, then the display will return to the last function being displayed before the ignition was turned to the Off position. With the ignition switch in the On position, momentarily depressing and releasing the Step push button (4) will cause the compass-mini-trip computer to change its mode of operation. Momentarily depressing and releasing the U.S./Metric push button (1) will cause the unit to toggle between U.S. and Metric measurements. Momentarily depressing and releasing the C/T (compass/temperature) push button (5) will cause the compass mini-trip computer to return to the compass/temperature display mode from any other mode. This compass mini-trip computer features several functions that can be reset. If the RESET push button (2) is depressed for more than one second with the ignition switch in the On position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 7742 Compass: Testing and Inspection COMPASS MINI-TRIP COMPUTER If the problem with the compass mini-trip computer is an inaccurate or scrambled display, refer to SELF- DIAGNOSTIC TEST. If the problem with the compass mini-trip computer is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 3. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Integrated Power Module (IPM), repair the open fused B(+) circuit as required. 3. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 4. If not OK, repair the open or shorted circuit as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the Electronic Overhead Module and the PCI data bus circuit. If not OK, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - PCI data bus Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required PCI bus messages are present on the PCI bus. If all required messages are present on the PCI bus, or if the ignition switch is turned to the Off position, the EOM will automatically return to normal operation. The required PCI bus messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine Off Duration message - Ambient Air Temperature message NOTE: - The Fuel Used message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 7743 - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 7744 Compass: Adjustments Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display. 3. Press and hold the Reset push button down until "VAR" appears in the display. This takes about five seconds. 4. Momentarily depress and release the STEP push button to step through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the Reset push button to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp Compass: Service and Repair Illumination Lamp WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: There are provisions for three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the head-liner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Compass Mini-Trip Computer (CMTC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 7747 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Compass Mini-Trip Computer (CMTC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the head-liner. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 7748 Compass: Service and Repair Compass Calibration CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement compass mini-trip computer modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variation number must also be reset. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display. 2. Depress and hold the RESET push button. Hold the push buttons down until "CAL" appears in the display. This takes about ten seconds. 3. Drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles in not less than 16 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: - A blank compass display indicates that vehicle degaussing (demagnetizing) is necessary. - If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure at least one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 7749 Compass: Service and Repair Compass Demagnetizing Degaussing Tool #6029 A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool atleast 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is atleast 61 centimeters (2 feet) from the screw head, disconnect the tool. 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool atleast 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool atleast 11 centimeters (4 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 7750 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is atleast 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 7751 Compass: Service and Repair Module - Compass Temperature REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the head-liner. 3. Remove the screws (4) that secure the Electronic Overhead Module (EOM) (2) to the overhead console housing (1). 4. Disconnect the overhead console wire harness connector from the EOM connector receptacle. 5. Remove the EOM (2) from the overhead console housing (1). INSTALLATION NOTE: If a new Electronic overhead Module (EOM) has been installed, the compass will have to be calibrated and the variance set. 1. Position the Electronic overhead Module (EOM) (2) onto the overhead console housing (1). 2. Reconnect the overhead console wire harness connector to the EOM connector receptacle. 3. Install the screws (4) that secure the EOM (2) to the overhead console housing (1). Tighten the screws to 2.2 N.m (20 in.lbs.). 4. Install the overhead console (1) onto the headliner. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 7752 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation Cruise Control Indicator Lamp: Description and Operation A cruise indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator consists of the word "CRUISE", which appears in the lower portion of the gear selector indicator Vacuum-Fluorescent Display (VFD) unit. The gear selector indicator VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The "CRUISE" text appears in a blue-green color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The cruise indicator is serviced as a unit with the VFD in the instrument cluster. The cruise indicator gives an indication to the vehicle operator when the speed control system is turned On, regardless of whether the speed control is engaged. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The cruise indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the cruise indicator for the following reasons: - Cruise Lamp-On Message - Each time the cluster receives a cruise lamp-on message from the PCM indicating the speed control system has been turned On, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a cruise lamp-off message from the PCM or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cruise indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the speed control switches to determine the proper outputs to the speed control servo. The PCM then sends the proper cruise indicator lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the speed control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the cruise indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation A door ajar indicator is standard equipment on all instrument clusters. The door ajar indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The door ajar indicator consists of a stencil-like cutout of the words "DOOR AJAR" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "DOOR AJAR" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The door ajar indicator is serviced as a unit with the instrument cluster. The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and hard wired inputs received by the cluster from the door ajar switches located in each door latch unit. The door ajar indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the door ajar indicator for the following reasons: - Door Ajar Switch Input - Each time the cluster detects ground on any one of the door ajar switch sense circuits (door ajar switch closed = door is open or not completely latched) the door ajar indicator will be illuminated. The indicator remains illuminated until all of the door ajar switch sense inputs to the cluster are an open circuit (door ajar switch open = door fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the door ajar indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the door ajar switches to determine the status of the doors. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 Module-Electronic Overhead (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 EOM System Schematic Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console Driver/Vehicle Information Display: Description and Operation Overhead Console An overhead console is available on this vehicle and includes the following components: - Front map/reading lamps - A blue-green vacuum-fluorescent display screen - if equipped with trip computer - Universal transmitter - if equipped - Electronic Overhead Module (EOM) The overhead console assembly is mounted by two snap clips and screws securing it to a molded plastic retainer bracket located above the headliner. The EOM is accessed by removing the overhead console from the bracket and pulling it away from the headliner. COMPASS DISPLAY All the available overhead consoles on this model include Compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle at 5 to 8 kilometers-per-hour (3 to 5 miles-per-hour), on level ground in a square shaped pattern. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing procedure may be required to restore proper compass operation. TEMPERATURE DISPLAY All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules, (CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the module over the Programmable Communications Interface (PCI) data bus circuit. For more information on the ambient temperature sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 7797 Driver/Vehicle Information Display: Description and Operation Universal Transmitter The universal transmitter transceiver is integral to the overhead console (7). The only visible component of the universal transmitter are the three transmitter push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as part of the Electronic Overhead Module (EOM). This unit includes the push button switches for both the transmitter and compass mini trip computer. The universal transmitter operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transmitter radio frequency codes to operate garage door openers, security gates and security lighting. The overhead console display provides visual feedback to the driver, showing which transmitter button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the transmitter system to enter the home. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console Driver/Vehicle Information Display: Testing and Inspection Overhead Console If the problem with the overhead console is an inaccurate or scrambled display, refer to SELFDIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 3. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Integrated Power Module (IPM), repair the open fused B(+) circuit as required. 3. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 4. If not OK, repair the open or shorted circuit as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the electronics module and the PCI data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 7800 Driver/Vehicle Information Display: Testing and Inspection Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - PCI data bus Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required PCI bus messages are present on the PCI bus. If all required messages are present on the PCI bus, or if the ignition switch is turned to the Off position, the EOM will automatically return to normal operation. The required PCI bus messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine Off Duration message - Ambient Air Temperature message NOTE: - The Fuel Used message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 7801 Driver/Vehicle Information Display: Testing and Inspection Universal Transmitter Radio Frequency Detector #9001 If both the Transmitter and the compass mini trip computer display are inoperative, refer to testing for further diagnosis. If the Universal Transmitter is inoperative, but the compass mini trip computer display is operating normally. Retrain the Transmitter with a known good transmitter as instructed and test the Transmitter operation again. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the universal transmitter assembly. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7804 Driver/Vehicle Information Display: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7805 Driver/Vehicle Information Display: Service and Repair Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7806 Driver/Vehicle Information Display: Service and Repair Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7807 Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7808 until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Erasing Transmitter Codes NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink is now in the train (or learning) mode and can be programmed at any time beginning with "Programming. Reprogramming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. To program a device to HomeLink using a HomeLink button previously trained, follow these steps: 1. Press and hold the desired HomeLink button. Do NOT release the button. 2. The EVIC display will show "Channel X Transmit" (where X is Channel 1, 2, or 3) for 20 seconds and then change to "Channel X Training". Without releasing the HomeLink button, proceed to step 3. 3. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 4. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7809 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation Electronic Throttle Control Indicator: Description and Operation An Electronic Throttle Control (ETC) indicator is standard equipment on all gasoline engine instrument clusters. However, on vehicles not equipped with the I/I optional 5.7 liter gasoline engine, this indicator is electronically disabled. The ETC indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Electronic Throttle Control" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system is faulty or inoperative. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ETC indicator is illuminated for about six seconds. The entire six second bulb test is a function of the PCM. - ETC Lamp-On Message - Each time the cluster receives a lamp-on message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about twelve seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. - Communication Error - If the cluster receives no ETC lamp messages for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected a system malfunction and/or that the ETC system is inoperative. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, the instrument cluster and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ETC indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation Four Wheel Drive Indicator Lamp: Description and Operation A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The service 4WD indicator consists of the text "SERV 4WD", which appears in the lower portion of the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "SERV 4WD" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the VFD in the instrument cluster. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TCCM over the Programmable Communications Interface (PCI) data bus. The service 4WD indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the service 4WD indicator for the following reasons: - Service 4WD Lamp-On Message - Each time the cluster receives a service 4WD lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-off message from the TCCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for five seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids Fuel Gauge: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids > Page 7820 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids > Page 7821 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids > Page 7822 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 7823 Fuel Gauge: Description and Operation A fuel gauge is standard equipment on all instrument clusters. This gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The fuel gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "E" (or Empty) to "F" (or Full). An International Control and Display Symbol icon for "Fuel" is located on the cluster overlay, directly below the right end of the gauge scale. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the "Fuel" icon in the fuel gauge to provide the driver with a reminder as to the location of the fuel filler access. On vehicles equipped with a diesel engine, text that specifies "DIESEL ONLY" is located across the fuel gauge below the gauge scale, but above the hub of the gauge needle. On all models except SRT-10 the fuel gauge graphics are black against a white field. On SRT-10 the gauge graphics are black against a silver field except for a single red graduation at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The fuel gauge is serviced as a unit with the instrument cluster. The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full, the cluster programming applies an algorithm to calculate the proper gauge needle position, then moves the gauge needle to the proper relative position on the gauge scale. The algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the PCM or ECM. - Less Than Fifteen Percent Tank Full Message - Each time the cluster receives messages from the PCM or ECM indicating the percent tank full is about fifteen percent or less for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, the gauge needle is moved to between the one-sixteenth and one-eighth graduations or below on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM or ECM indicating that the percent tank full is greater than about fifteen percent for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled off and then on again by the appropriate percent tank full messages from the PCM or ECM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is less than empty, the gauge needle is moved to the far left end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is a short circuit. - more than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is more than full, the gauge needle is moved to the far left end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is an open circuit. - Communication Error - If the cluster fails to receive a percent tank full message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the fuel gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel tank sending unit to determine the level of the fuel in the fuel tank. On vehicles with a diesel engine, the ECM continually monitors the fuel tank sending unit to determine the level of the fuel in the fuel tank. The PCM or ECM then sends the proper fuel level messages to the instrument cluster. For further diagnosis of the fuel gauge or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the fuel tank sending unit, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 7824 control the fuel gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 7829 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7833 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7834 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7835 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7836 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7837 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7838 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7839 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7841 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7843 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7844 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7845 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7846 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7847 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7848 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 7852 Fuel Gauge Sender: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 7853 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Description and Operation Lamp Out Indicator: Description and Operation A lamp out indicator is standard equipment on all instrument clusters. The lamp out indicator consists of the words "LAMP OUT", which appear in the lower portion of the odometer/trip odometer Vacuum-Fluorescent Display (VFD) unit. The odometer/trip odometer VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the lamp out indicator from being clearly visible when it is not illuminated. The words "LAMP OUT" appear in an amber color and at the same lighting level as the odometer/trip odometer information when they are illuminated by the instrument cluster electronic circuit board. The lamp out indicator is serviced as a unit with the VFD in the instrument cluster. The lamp out indicator gives an indication to the vehicle operator when an exterior lamp has failed. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The lamp out indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the lamp out indicator for the following reasons: - Lamp Out Indicator Lamp-On Message - Each time the cluster receives a lamp out indicator lamp-on message from the FCM indicating that an inoperative headlamp (low or high beam), turn signal lamp, or brake lamp (excluding Center High Mounted Stop Lamp [CHMSL]) circuit has been detected with the ignition switch in the On position, the lamp out indicator is illuminated solid. The indicator remains illuminated until the cluster receives a lamp out indicator lamp-off message from the FCM or until the ignition switch is turned to the Off position, whichever occurs first. If the lamp-on message is received when the ignition is first turned to the On position, the lamp out indicator is flashed at a fast rate (1 Hertz) for about thirty seconds before illuminating solid. - Actuator Test - Each time the cluster is put through the actuator test, the lamp out indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM monitors each of the headlamp, turn signal lamp, and brake lamp (except CHMSL) circuits to determine the condition of these exterior lamps. The FCM then sends the proper lamp out indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the lamp out indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the exterior lighting system circuits, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the lamp out indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation A low fuel indicator is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The low fuel indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Fuel" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The low fuel indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the low fuel indicator is illuminated for about two seconds as a bulb test. - Less Than Fifteen Percent Tank Full Message - Each time the cluster receives messages from the PCM or ECM indicating the percent tank full is about fifteen percent or less for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, the fuel gauge needle is moved to between the one-sixteenth and one-eighth graduations or below on the gauge scale, the low fuel indicator is illuminated and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM or ECM indicating that the percent tank full is greater than about fifteen percent for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled off and then on again by the appropriate percent tank full messages from the PCM or ECM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is less than empty, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is a short circuit. - More Than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is more than full, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the low fuel indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. On vehicles with a diesel engine, the ECM continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The PCM or ECM then sends the proper fuel level messages to the instrument cluster. For further diagnosis of the low fuel indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the fuel tank sending unit, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the low fuel indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC's, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. On vehicles with a diesel engine, the ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation An odometer and trip odometer are standard equipment in all instrument clusters. The odometer, trip odometer, and engine hours information are displayed BBBSB.S"" in a common electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The odometer, trip odometer, and engine hours information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/trip odometer switch button that extends through the lower edge of the cluster lens, just left of the odometer VFD. When the trip odometer information is displayed, the word "TRIP" is also illuminated in the upper right corner of the VFD in a blue-green color and at the same lighting level as the trip odometer information. On all models except SRT-10, the engine hours information replaces the selected odometer or trip odometer information whenever the ignition switch is in the On position and the engine is not running. The engine hours feature is disabled on all SRT-10 models. The odometer, trip odometer, and engine hours information is stored in the instrument cluster memory. This information can be increased when the proper inputs are provided to the instrument cluster, but the information cannot be decreased. The odometer can display values up to 999,999 kilometers (999,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 9,999.9 kilometers (9,999.9 miles) before it rolls over to zero. Engine hours are displayed in the format, "hr9999". The cluster will accumulate values up to 9,999 hours before the display rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), while the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. The odometer also has a "Rental Car" mode, which will illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions. During daylight hours (exterior lamps are Off) the odometer VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The odometer/trip odometer VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. On all models except SRT-10, the engine hours give an indication of the cumulative engine-on time. The engine hours feature is disabled on SRT-10 models. This indicator is controlled by the instrument cluster circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) or Engine Control Module (ECM) over the Programmable Communications Interface (PCI) data bus. The odometer, trip odometer and engine hours information is displayed by the instrument cluster odometer Vacuum Fluorescent Display (VFD). The odometer VFD will display the odometer information whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions, and will display the last previously selected odometer or trip odometer information when the ignition switch is turned to the On or Start positions. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch button momentarily with the VFD illuminated will toggle the display between the odometer and trip odometer information. Each time the VFD is illuminated with the ignition switch in the On or Start positions, the display will automatically return to the last mode previously selected (odometer or trip odometer). - Engine Hours Display Toggling - When the trip odometer reset switch button is pressed and held for longer than about six seconds with the ignition switch in the On position and the engine speed message from the PCM is zero, the trip odometer information will be momentarily displayed, then the engine hours information will be displayed. The VFD must be displaying the odometer information when the trip odometer reset switch button is pressed in order to toggle to the engine hours display. The engine hours will remain displayed for about thirty seconds, until the engine speed message is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. - Trip Odometer Reset - When the trip odometer reset switch button is pressed and held for longer than about two seconds with the ignition switch in the On or Start position, the trip odometer will be reset to 0.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to be reset. - Communication Error - If the cluster fails to receive a distance message during normal operation, it will hold and display the last data received until the ignition switch is turned to the Off position. If the cluster does not receive a distance message within one second after the ignition switch is turned to the On position, it will display the last distance message stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD will display all dashes. - Actuator Test - Each time the cluster is put through the actuator test, the odometer VFD will display all of its segments simultaneously during the VFD portion of the test to confirm the functionality of each of the VFD segments and the cluster control circuitry. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 7873 The PCM continually monitors the vehicle speed pulse information received from the vehicle speed sensor or the Controller Anti-lock Brake (CAB) and engine speed pulse information received from the crankshaft position sensor, then sends the proper distance and engine speed messages to the instrument cluster. For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions, refer to testing. For proper diagnosis of the vehicle speed sensor, the crankshaft position sensor, the CAB, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the odometer/trip odometer, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "100" psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT-10 the oil pressure gauge graphics are black against a white field except for two red graduations at the low end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT-10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT-10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduations (except SRT-10) or to the red zone (SRT-10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Right Side Engine (5.7L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 Switch-Oil Pressure (Except SRT) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Description and Operation Oil Temperature Gauge: Description and Operation An oil temperature gauge (1) is standard equipment on all SRT-10 models. This electronic, analog gauge is located in the lower end of the left A-pillar trim molding below the grab handle (2), in clear view of the vehicle operator. The gauge dial face is visible through a clear plastic lens, which is secured to the gauge housing with a silver anodized trim ring. The remainder of the gauge, including the mounting provisions and the electrical connections, are concealed behind the left A-pillar trim molding. The molded plastic housing at the rear of the gauge protects the electronic circuitry of the gauge and has two mounting studs, which are secured by nuts to a molded plastic mounting bracket screwed to the back of the A-pillar trim molding. A short pigtail wire with a connector extends from the back of the gauge housing and connects the gauge to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The oil temperature gauge consists of a movable gauge needle or pointer with a 270 degree sweep that is controlled by the electronic gauge circuitry. The gauge overlay reads left-to-right from "60" to "150" with "° C" indicated directly below the low (left) end of the scale in markets where a metric instrument cluster is specified, or from "140" to "300" with "° F" indicated directly below the left end of the scale for all other markets. The text "OIL TEMP" is imprinted on the center of the gauge overlay below the hub of the gauge needle, while the text "SRT" is imprinted above the hub of the gauge needle. The gauge graphics are black against a silver field except for a single red zone at the high (right) end of the gauge scale and are clearly visible in daylight. General illumination lighting for the gauge is provided by a Light Emitting Diode (LED) that is soldered onto the gauge circuit board. The gauge overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with the gauge dial face and graduations, but this layer is also translucent. The underlying layer of the overlay is opaque and allows light from the LED on the circuit board behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. When illuminated from behind by the panel lamps dimmer controlled gauge lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Description and Operation > Page 7906 The oil temperature gauge cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The gauge illumination LED unit is not available for service replacement and, if damaged or faulty, the entire gauge must be replaced. The oil temperature gauge gives an indication to the vehicle operator of the engine oil temperature. This gauge is controlled by its own internal electronic circuit board based upon a hard wired input received by the gauge from an oil temperature sensor (4) installed in a tapped hole that penetrates an oil passage on the right side of the engine block (2) just behind the oil pressure sensor (3). The oil temperature sensor is a Negative Temperature Coefficient (NTC) thermistor that changes its internal resistance with changes in temperature. The sensor has two terminals. One terminal receives a hard wired ground path through a take out and connector of the engine wire harness (1), and the second terminal provides a variable output to the gauge through the same take out and connector. As the oil temperature increases the resistance of the sensor decreases, and as the oil temperature decreases the resistance of the sensor increases. The oil temperature gauge is an air core magnetic unit. The gauge pigtail wire and connector provides the gauge electronic circuit board with a hard wired ground path, battery current through a fused ignition switch output (run-start) circuit, a Pulse Width Modulated (PWM) panel lamps dimmer input from the instrument cluster for general illumination, and the input from the oil temperature sensor. This gauge is only operational when the ignition switch is in the On or Start positions. The gauge electronic circuit board reads the input from the oil temperature sensor, then provides linear positioning of the gauge needle on the gauge scale based upon that input. The gauge electronics will move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The oil temperature gauge and the oil temperature sensor may be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Description and Operation > Page 7907 Oil Temperature Gauge: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired oil temperature gauge and gauge lighting circuits may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When testing the oil temperature gauge by alternately opening and shorting the oil temperature sensor signal circuit, the gauge pointer may rotate in either direction (clockwise or counterclockwise) to reach the objective point on the gauge scale. This is a normal condition as the gauge electronics are programmed to move the pointer from its current position to the objective position in the direction that provides the shortest pointer travel distance. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Description and Operation > Page 7908 Oil Temperature Gauge: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim molding (5) from the inside of the left A-pillar. 3. Remove the two nuts (2) that secure the oil temperature gauge (4) mounting studs to the mounting bracket (1) on the back of the A-pillar trim. 4. Remove the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. 5. Remove the mounting bracket from the back of the A-pillar trim. 6. Push the gauge and the gauge pigtail wire (6) and connector out through the mounting hole on the face of the A-pillar trim. INSTALLATION 1. Position the oil temperature gauge (4) into the mounting hole on the face of the A-pillar trim (5). 2. Position the mounting bracket (1) to the back of the A-pillar trim with the gauge pigtail wire (6) and connector routed between the two lower mounting bracket screw bosses on the back of the A-pillar trim. 3. Install and tighten the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. Tighten the screws to 1 N.m (9 in.lbs.). 4. Align and insert the two mounting studs on the back of the gauge housing through the appropriate holes in the mounting bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Description and Operation > Page 7909 5. Install and tighten the two nuts that secure the gauge mounting studs to the mounting bracket. Tighten the nuts to 0.5 N.m (5 in.lbs.). 6. Reinstall the trim molding onto the inside of the left A-pillar. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The tow/haul indicator consists of the text "TOW/HAUL", which appears in the lower portion of the odometer/trip odometer indicator Vacuum Fluorescent Display (VFD) unit. The odometer/trip odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "TOW/ HAUL" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The tow/haul indicator is serviced as a unit with the VFD in the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the Off position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tow/haul indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the Off position of the tow/haul switch has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation A brake indicator is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of a stencil-like cutout of the word "BRAKE" and the International Control and Display Symbol icon for "Brake Failure" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the brake indicator is illuminated by the instrument cluster for about two seconds as a bulb test. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. The CAB can also send brake lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the On position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to testing. The park brake switch input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 7916 Parking Brake Warning Lamp: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired park brake switch input to the EMIC may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Antilock Brake (CAB), the Programmable Communications Interface (PCI) data bus, or the electronic message inputs also used by the EMIC to provide brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAB, the PCI data bus, and the electronic message inputs for the brake indicator operation requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7920 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7921 Switch-Parking Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7922 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7923 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7924 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7925 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the Off position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about sixty seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 13 kilometers-per-hour (8 miles-per-hour), the seatbelt indicator will begin to cycle between flashing on and off for five seconds, then lighting solid for three seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for twelve complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Airbag Control Module (ACM), store a Diagnostic Trouble Code (DTC) in the cluster memory, then flash the seatbelt indicator on and off. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The seatbelt switch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, refer to testing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming Seat Belt Reminder Lamp: Service and Repair Enhanced Seatbelt Reminder Programming The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The beltminder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming > Page 7931 Seat Belt Reminder Lamp: Service and Repair Customer Programming Sequence NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. 1. With the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except On or Start to toggle the beltminder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 7943 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 7966 Fuel Gauge Sender: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 7967 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7974 Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7975 Switch-Parking Brake Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7976 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7977 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7978 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7979 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Diagrams Sensor-Water In Fuel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation A speedometer is standard equipment on all instrument clusters. The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face. For all models except SRT-10 the speedometer reads left-to-right either from "0" to "120" mph, or from "0" to "200" km/h, depending upon the market for which the vehicle is manufactured. On SRT-10 the speedometer reads left-to-right either from "0" to "160" mph, or from "0" to "280" km/h, depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay just below the hub of the speedometer needle abbreviates the unit of measure for the primary scale (i.e.: MPH or km/h), followed by the unit of measure for the secondary scale. The speedometer graphics for all models except SRT-10 are black (primary scale) and blue (secondary scale) against a white field. On SRT-10 the gauge graphics are black (primary scale) and gray (secondary scale) against a silver field and also includes a line of text identifying this as a "Performance Vehicle Operations" product. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the blue or gray graphics appear light blue. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The speedometer is serviced as a unit with the instrument cluster. The speedometer gives an indication to the vehicle operator of the relative vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Vehicle Speed Message - Each time the cluster receives a vehicle speed message from the PCM it will calculate the correct vehicle speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster will receive a new vehicle speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be positioned at the relative vehicle speed position on the gauge scale until the vehicle stops moving, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive a speedometer message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the gauge needle will return to the left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the speedometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the vehicle speed sensor or the Controller Anti-lock Brake (CAB) to determine the vehicle road speed. The PCM then sends the proper vehicle speed messages to the instrument cluster. For further diagnosis of the speedometer or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the vehicle speed sensor, the CAB, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the speedometer, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation A tachometer is standard equipment on all instrument clusters. The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face. The tachometer reads left-to-right from "0" to "7" for gasoline engines. On vehicles with a diesel engine, the scale reads from "0" to "5". On all models except SRT-10, the text "RPM X 1000" is imprinted on the cluster overlay directly below the hub of the tachometer needle. On SRT-10 models the text "X 1000 RPM" is imprinted on the cluster overlay directly below the hub of the tachometer needle. This text identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. On all models except SRT-10 the tachometer graphics are black against a white field, making them clearly visible within the instrument cluster in daylight. On SRT-10 the tachometer graphics are black against a silver field except for red graduations beginning at the "6" increment and at each 250 rpm increment to the "7" at the high end of the scale. The SRT-10 tachometer also includes the text, "Premium Unleaded Fuel Only." In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The tachometer is serviced as a unit with the instrument cluster. The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Speed Message - Each time the cluster receives an engine speed message from the PCM or ECM it will calculate the correct engine speed reading and position the gauge needle at that relative engine speed position on the gauge scale. The cluster will receive a new engine speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be repositioned at the relative engine speed position on the gauge scale until the engine stops running, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine speed message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the gauge needle will return to the left end of the gauge scale. Actuator Test - Each time the cluster is put through the actuator test, the tachometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry On vehicles with a gasoline engine, the PCM continually monitors the crankshaft position sensor to determine the engine speed. On vehicles with a diesel engine, the ECM continually monitors the engine speed sensor to determine the engine speed. The PCM or ECM then sends the proper engine speed messages to the instrument cluster. For further diagnosis of the tachometer or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the crankshaft position sensor, the engine speed sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tachometer, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "260"° F in all other markets. On vehicles with a diesel engine, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "245"° F in all other markets. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay directly below the left end of the gauge scale. On all models except SRT-10 the engine coolant temperature gauge graphics are black against a white field except for two red graduations at the high end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, about or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the left end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved into the red zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains in the red zone and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. On vehicles with a diesel engine, the ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The transmission over-temperature indicator consists of a stencil-like cutout of the text "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED. For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Upshift Indicator > Component Information > Description and Operation Upshift Indicator: Description and Operation An upshift indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with a manual transmission, or on vehicles equipped with a manual transmission but sold in a market where this is not required equipment, this indicator is electronically disabled. The upshift indicator consists of an upward pointed arrow icon, which appears on the right side of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The icon appears in a blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The upshift indicator is serviced as a unit with the instrument cluster. The upshift indicator gives an indication to the vehicle operator when the manual transmission should be shifted to the next highest gear in order to achieve the best fuel economy. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles with a diesel engine over the Programmable Communications Interface (PCI) data bus. The upshift indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the upshift indicator for the following reasons: - Upshift Lamp-On Message - Each time the cluster receives an upshift lamp-on message from the PCM or ECM indicating the engine speed and load conditions are right for a transmission upshift to occur, the upshift indicator is illuminated. The indicator remains illuminated until the cluster receives an upshift lamp-off message from the PCM or ECM, or until the ignition switch is turned to the Off position, whichever occurs first. The PCM or ECM will normally send an upshift lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The indicator will then remain off until the vehicle stops accelerating and is brought back into the range of indicator operation, or until the transmission is shifted into another gear. - Actuator Test - Each time the cluster is put through the actuator test, the upshift indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine speed and load conditions to determine the proper fuel and ignition requirements. On vehicles with a diesel engine, the ECM continually monitors the engine speed and load conditions to determine the proper fuel requirements. The PCM or ECM then sends the proper upshift indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the upshift indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the upshift indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation A voltage gauge is standard equipment on all instrument clusters. The voltage gauge is located in the upper left quadrant of the instrument cluster, above the fuel gauge. The voltage gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "10" to "18" volts. On vehicles with a diesel engine, the scale reads from "8" to "18" volts. An International Control and Display Symbol icon for "Battery Charging Condition" is located on the cluster overlay, directly below the right end of the gauge scale. On all models except SRT-10 the voltage gauge graphics are black against a white field except for a single red graduation at each end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red graduation at the left end of the gauge scale and two red graduations at the right end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The voltage gauge is serviced as a unit with the instrument cluster. The voltage gauge gives an indication to the vehicle operator of the electrical system voltage. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The voltage gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the left end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - System Voltage Message - Each time the cluster receives a system voltage message from the PCM or ECM indicating the system voltage is between about 9.5 volts and about 15 volts, the gauge needle is moved to the relative voltage position on the gauge scale. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is less than about 9 volts (charge fail condition) or that the battery temperature sensor input is an open circuit, the gauge needle is moved to the graduation on the far left end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the far left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is greater than about 9.5 volts (but less than about 15.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. On vehicles equipped with the optional diesel engine, the ECM is programmed to restrict the voltage gauge needle to a position above the graduation on the far left end of the gauge scale and suppress the check engine indicator operation until after the engine intake manifold air heater has completed a pre-heat or post-heat cycle. - System Voltage High Message - On all models except SRT-10, each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is greater than about 15.5 volts, the gauge needle is moved to the graduation on the far right end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the right end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. On SRT-10, each time the cluster receives three consecutive messages from the PCM indicating the electrical system voltage is greater than about 15.5 volts, the gauge needle is moved to the 16 volt graduation of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at or above the 16 volt graduation of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive a system voltage message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the far left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the voltage gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry On vehicles with a gasoline engine, the PCM continually monitors the system voltage to control the generator output. On vehicles with a diesel engine, the ECM continually monitors the system voltage to control the generator output. The PCM or ECM then sends the proper system voltage messages to the instrument cluster. For further diagnosis of the voltage gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 8007 For proper diagnosis of the charging system, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the voltage gauge, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Diagrams Sensor-Water In Fuel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 Backup Lamp Switch: Connector Views Switch-Back Up Lamp (Gas) Switch-Back Up Lamp (5.7L NV5600) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 8040 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 8041 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the faulty backup lamp switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views Brake Lamp: Connector Views Lamp-Tail Stop Turn-Left (Box Off) Lamp-Tail Stop Turn-Left (Box On) Lamp-Tail Stop Turn-Right (Box On) Lamp-Tail Stop Turn-Right (Box On) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 8046 Brake Lamp: Description and Operation The brake (or stop) lamps each have a path to ground at all times through a takeout and eyelet terminal of the left headlamp and dash wire harness that is secured by a ground screw to the left inner fender support within the engine compartment. The Center High Mounted Stop Lamp (CHMSL) has a path to ground at all times through a takeout and eyelet terminal of the instrument panel wire harness that is secured by a ground screw to the back of the support structure of the instrument panel near the center. The brake lamps receive battery voltage from the Front Control Module (FCM) on the right and left brake lamp feed circuits and the CHMSL receives battery voltage from the brake lamp switch output circuit when the brake lamp switch is closed by the brake pedal arm. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 8047 Brake Lamps Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8051 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8052 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8053 Switch-Stop Lamp Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8054 Brake Light Switch: Description and Operation The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, faulty, or removed from its mounting position for any reason, it must be replaced with a new unit. The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Power-train Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned On and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch is diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8055 Brake Light Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. Brake Lamp Switch Tests 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the faulty brake lamp switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8056 Brake Light Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (1) near the support bracket on the lower steering column (3). 3. Disconnect the wire harness connector (5) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket (4). 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch. INSTALLATION CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket (4) on the lower steering column (3). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (1) is firmly Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8057 seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (5) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation Cargo Lamp: Description and Operation A cargo lamp indicator is standard equipment on all instrument clusters. The cargo lamp indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The cargo lamp indicator consists of a stencil-like cutout of the words "CARGO LAMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "CARGO LAMP" text to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The cargo lamp indicator is serviced as a unit with the instrument cluster. The cargo lamp indicator gives an indication to the vehicle operator when the exterior cargo lamp is illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, a hard wired multiplex input received by the cluster from the panel lamps dimmer switch on the headlamp dimmer switch mux circuit, and electronic unlock request messages received from the optional Remote Keyless Entry (RKE) module. The cargo lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the cargo lamp indicator for the following reasons: - Cargo Lamp-On Input - Each time the cluster detects a cargo lamp-on input from the headlamp switch on the headlamp dimmer switch mux circuit, the cargo lamp and the cargo lamp indicator will be illuminated. The cargo lamp and indicator remain illuminated until the cluster receives a cargo lamp-off input from the headlamp switch, until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cargo lamp indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the headlamp dimmer switch circuit to determine the proper interior lamps features and panel lamps illumination levels to provide. The cluster then energizes and de-energizes a low side driver circuit to control the exterior cargo lamp. Each time the instrument cluster energizes the cargo lamp driver and the ignition switch is in the On or Start positions, the cluster also turns on the cargo lamp indicator. For further diagnosis of the cargo lamp indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the cargo lamp or the headlamp switch inputs to the instrument cluster that control the cargo lamp indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Page 8061 Cargo Lamp: Service and Repair NOTE: The Center High Mounted Stop Lamp (CHMSL) houses three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets on the back of the lamp. 4. Firmly grasp the socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Page 8062 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 N.m (20 in.lbs.). 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL NOTE: The Center High Mounted Stop Lamp (CHMSL) houses three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets on the back of the lamp. 4. Firmly grasp the socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The Center High Mounted Stop Lamp (CHMSL) houses three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. 1. Align the base of the bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Page 8067 3. Align the socket and bulb with the keyed opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 N.m (20 in.lbs.). 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Clearance Lamp Bulb > Component Information > Service and Repair Clearance Lamp Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cab clearance lamp (1) from the roof panel. 3. Pull the base of the bulb (3) straight out of the socket (2). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Reinstall the cab clearance lamp (1) onto the roof panel. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Lamp-Glove Box Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 8076 Glove Box Lamp: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window (3) in the instrument panel glove box opening (1) to access the bulb on the side of the glove box lamp and switch unit (2). 4. Pull the base of the bulb straight out of the bulb holder. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Reach through the window (3) in the instrument panel glove box opening (1) to align the base of the bulb with the bulb holder on the side of the glove box lamp and switch unit (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 8077 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Close the glove box door. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair > Page 8081 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation Vehicles manufactured for sale in Canada illuminate the high beam filament of both headlamp bulbs at a reduced intensity when the engine is running and the exterior lamps are turned off. The FCM must be programmed with the appropriate country code for this feature to be enabled. Once enabled, anytime the FCM receives electronic messages over the PCI data bus from the PCM indicating the engine is running and from the EMIC indicating the status of the headlamp switch exterior lighting input is Off, the FCM provides a pulse width modulated voltage output to the proper headlamp bulb filaments through the right and left high beam output circuits to produce illumination at a reduced intensity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation > Page 8085 Daytime Running Lamp: Testing and Inspection NOTE: Before performing the following tests, determine whether the headlamp low and high beams operate. If the headlamp low and high beams are also inoperative, diagnose and repair that problem before attempting to repair the Daytime Running Lamps. Daytime Running Lamps Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair NOTE: There are two types of dome lamps available in this model: one with a switch (2) that is activated by depressing the lamp lens, and one without a switch. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the dome lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the dome lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the ends of the bulb (3) with the two bulb holders within the dome lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the housing. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. 2. Reach under and behind the front fascia to access the front fog lamp housing (1) on the back of the front bumper (4). 3. Disconnect the wire harness connector (3) from the fog lamp bulb (2). 4. Firmly grasp the bulb on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the bulb straight out from the keyed opening in the housing. INSTALLATION CAUTION: - Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. - Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the fog lamp bulb (2) with the keyed opening on the back of the front fog lamp housing (1). 2. insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. The bulb connector receptacle should be pointed straight downward. 4. Reconnect the wire harness connector (3) to the bulb. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8103 Fog/Driving Lamp Relay: Description and Operation The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The front fog lamp relay is located in the Power Distribution Center (PDC)See: Maintenance/Fuses and Circuit Breakers/Relay BoxApplications and ID in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the front fog lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the front fog lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the front fog lamps through a fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the lock ring (2) that secures the headlamp bulb socket (3) on the back of the front lamp unit housing (1) and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the lock ring, socket and bulb straight out from the keyed opening in the housing. 5. Remove the socket and bulb from the lock ring. INSTALLATION CAUTION: - Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. - Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8108 1. Position the headlamp socket and bulb (3) into the keyed opening on the back of the front lamp unit housing (1) until it is firmly seated. 2. Install the lock ring (2) over the base of the socket and bulb (3). 3. Push the lock ring down over the socket and bulb until it is firmly seated. 4. Rotate the lock ring clockwise about 30 degrees to lock it into place. 5. Reinstall the front lamp unit (1) onto the front fender. 6. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8112 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8113 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8114 Switch-Headlamp Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8115 Headlamp Switch: Description and Operation The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (3) for exterior lighting control and a thumbwheel (2) for panel lamps dimming and interior lighting control. An optional switch has the same thumbwheel, but has an additional "Pull" function added to the rotary knob for selecting the optional front fog lamps. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and has a raised center lever to ease operator control. The thumbwheel is also plastic and knurled. The optional front fog lamp rotary knob is plastic with a smooth finish and an International Control and Display Symbol icon for "Front Fog Light" applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. The headlamp switch uses two resistor multiplexed outputs to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, and on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. - Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is pulled out to activate or pushed in to deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The FCM responds by energizing or de-energizing the front fog lamp relay in the Power Distribution Center (PDC). - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the FCM over the PCI data bus. The FCM responds by energizing or de-energizing the park lamp relay in the PDC and the high or low beam headlamp circuits. The FCM remembers which headlamp beams were last selected using the multi-function switch, and energizes those beams by default the next time the headlamps are turned On. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome defeat, dome on, parade/funeral mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the PCI data bus, and/or the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to and PWM processing of the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8116 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the left bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the instrument panel wire harness connector from the back of the headlamp switch. Headlamp Switch Tests 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the faulty headlamp switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8117 Headlamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch (4) and the left bezel (1) from the instrument panel (2) as a unit. 3. Disconnect the instrument panel wire harness connector (3) from the back of the headlamp switch. 4. Remove the three screws (3) that secure the headlamp switch (2) to the back of the instrument panel bezel (1). 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8118 1. Position the headlamp switch (2) to the back of the left instrument panel bezel (1). 2. Install and tighten the three screws (3) that secure the headlamp switch to the instrument panel bezel. Tighten the screws to 2 N.m (20 in.lbs.). 3. Position the left bezel (1) close enough to the instrument panel (2) to reconnect the instrument panel wire harness connector (3) to the back of the headlamp switch (4). 4. Reinstall the left bezel and the headlamp switch onto the instrument panel as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation A high beam indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The high beam indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "High Beam" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in blue through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. The high beam indicator gives an indication to the vehicle operator whenever the headlamp high beams are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired multiplex input received by the cluster from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit. The high beam indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the high beam indicator for the following reasons: High Beam Headlamps-On Input - Each time the cluster detects a high beam headlamps-on input from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit, the headlamp high beams and the high beam indicator will be illuminated. The headlamp high beams and the high beam indicator remain illuminated until the cluster receives a high beam headlamps-off input from the multi-function switch, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the high beam indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the headlamp switch and the multi-function switch to determine the proper headlamp low beam and high beam control. The instrument cluster then sends the proper low beam and high beam lamp-on and lamp-off messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus and turns the high beam indicator on or off accordingly. For further diagnosis of the high beam indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the headlamps, or the headlamp switch and multi-function switch inputs to the instrument cluster that control the high beam indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams Switch-Horn Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 8126 Horn Switch: Description and Operation The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 8127 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Description and Operation Lamp Out Indicator: Description and Operation A lamp out indicator is standard equipment on all instrument clusters. The lamp out indicator consists of the words "LAMP OUT", which appear in the lower portion of the odometer/trip odometer Vacuum-Fluorescent Display (VFD) unit. The odometer/trip odometer VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the lamp out indicator from being clearly visible when it is not illuminated. The words "LAMP OUT" appear in an amber color and at the same lighting level as the odometer/trip odometer information when they are illuminated by the instrument cluster electronic circuit board. The lamp out indicator is serviced as a unit with the VFD in the instrument cluster. The lamp out indicator gives an indication to the vehicle operator when an exterior lamp has failed. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The lamp out indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the lamp out indicator for the following reasons: - Lamp Out Indicator Lamp-On Message - Each time the cluster receives a lamp out indicator lamp-on message from the FCM indicating that an inoperative headlamp (low or high beam), turn signal lamp, or brake lamp (excluding Center High Mounted Stop Lamp [CHMSL]) circuit has been detected with the ignition switch in the On position, the lamp out indicator is illuminated solid. The indicator remains illuminated until the cluster receives a lamp out indicator lamp-off message from the FCM or until the ignition switch is turned to the Off position, whichever occurs first. If the lamp-on message is received when the ignition is first turned to the On position, the lamp out indicator is flashed at a fast rate (1 Hertz) for about thirty seconds before illuminating solid. - Actuator Test - Each time the cluster is put through the actuator test, the lamp out indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM monitors each of the headlamp, turn signal lamp, and brake lamp (except CHMSL) circuits to determine the condition of these exterior lamps. The FCM then sends the proper lamp out indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the lamp out indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the exterior lighting system circuits, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the lamp out indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair NOTE: This procedure is for pick-up models only. On cab and chassis models the license plate lamp is integral to the left rear lamp unit. The park/ brake/turn signal bulb within the left rear lamp unit provides illumination for the license plate lamp function on all cab and chassis models. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the rear bumper near the center to access the back of either of the two license plate lamp housings (3). 3. Firmly grasp the socket (2) on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb (1) straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (1) with the license plate lamp socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the license plate lamp housing (3). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof Map Light Bulb: Service and Repair Without Sunroof NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small thin-bladed screwdriver, gently pry between each side of the lamp lens and the overhead console housing (1) to unsnap the pivot tabs (3) on the lens from the pivots in the lamp housing. 3. With the lens disengaged from both pivots, pull the front of the lens forward far enough to disengage the tab (2) on the rear edge of the lens from the slot in the rear of the overhead console lamp housing. 4. Remove the lens from the housing. 5. Carefully unsnap the bulb (2) from the two bulb holders (1) within the overhead console lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof > Page 8140 1. Align the ends of the bulb (2) with the two bulb holders (1) within the overhead console lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Position the lens tab (2) into the slot in the rear of the overhead console (1) lamp housing. 4. Align the pivot tabs (3) on each side of the lens with the pivots within the overhead console lamp housing. 5. Press firmly and evenly on the lens over both pivot locations until both pivot tabs snap back onto the pivots within the housing. 6. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof > Page 8141 Map Light Bulb: Service and Repair With Sunroof NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the head-liner. 3. Firmly grasp the back of the reading lamp bulb socket (1) and unsnap it from the overhead console lamp housing. 4. Pull the socket and bulb (2) straight out from the keyed opening in the lamp housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the overhead console reading lamp bulb (2) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of lamp housing in the overhead console. 4. Insert the socket and bulb into the housing and press firmly on the back of the socket until it snaps into place and is firmly seated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof > Page 8142 5. Reinstall the overhead console onto the headliner. 6. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender Marker Lamp Bulb: Service and Repair Rear Fender NOTE: These lamps are used on pick-up models with dual rear wheels. A lamp with an amber lens is located on the rear fender ahead of each rear wheel opening, and a lamp with a red lens is located on the rear fender behind each rear wheel opening. The bulb types and service procedures are identical for all four of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using hand pressure, press the rear edge of the rear fender marker lamp lens/housing (4) toward the front of the vehicle against the spring pressure of the retaining clip, then pull the rear edge of the lamp outward to disengage it from the mounting hole in the rear fender. 3. Pull the lamp out from the rear fender far enough to access the bulb socket (1) on the back of the lamp lens/housing. 4. Firmly grasp the bulb socket on the back of the lamp lens/housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber O-ring seal (2) is properly installed and in good condition around the base of the bulb socket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender > Page 8148 4. Align the socket and bulb with the keyed opening on the back of the rear fender marker lamp lens/ housing (4). 5. Insert the socket and bulb into the housing until the socket is firmly seated. 6. Rotate the socket clockwise about 30 degrees to lock it into place. 7. Engage the front edge of the marker lamp into the front edge of the mounting hole in the rear fender. 8. Using hand pressure, press the rear edge of the marker lamp lens/housing toward the front of the vehicle against the spring pressure of the retaining clip, then push the rear edge of the lamp into the rear of the mounting hole in the rear fender. 9. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender > Page 8149 Marker Lamp Bulb: Service and Repair Tailgate NOTE: This lamp is used on pick-up models with dual rear wheels. A lamp with a red lens and containing three bulbs is located on the outside of the tailgate below the tailgate latch release handle. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the outboard ends of the tailgate marker lamp lens/housing (1) to the outer tailgate panel. 3. Pull the marker lamp out from the tailgate far enough to access the sockets (2) on the back of the lamp housing. 4. Firmly grasp the marker lamp socket on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the tailgate marker lamp lens/housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender > Page 8150 6. Position the marker lamp to the outer tailgate panel. 7. Install and tighten the two screws that secure the marker lamp lens/housing to the tailgate panel. Tighten the screws to 1 N.m (11 in.lbs.). 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8155 Parking Lamp Relay: Description and Operation The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The park lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the park lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact point away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the park lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the park lamps through a park lamp relay output circuit and provides battery voltage to the park lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (2) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 8159 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb (2) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8164 Fog/Driving Lamp Relay: Description and Operation The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The front fog lamp relay is located in the Power Distribution Center (PDC)See: Maintenance/Fuses and Circuit Breakers/Relay BoxApplications and ID in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the front fog lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the front fog lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the front fog lamps through a fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8168 Parking Lamp Relay: Description and Operation The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The park lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the park lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact point away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the park lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the park lamps through a park lamp relay output circuit and provides battery voltage to the park lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Manual Transmission (5.7L/Diesel) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 Figure 1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 Backup Lamp Switch: Connector Views Switch-Back Up Lamp (Gas) Switch-Back Up Lamp (5.7L NV5600) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 8196 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 8197 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the faulty backup lamp switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8201 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8202 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8203 Switch-Stop Lamp Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8204 Brake Light Switch: Description and Operation The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, faulty, or removed from its mounting position for any reason, it must be replaced with a new unit. The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Power-train Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned On and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch is diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8205 Brake Light Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. Brake Lamp Switch Tests 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the faulty brake lamp switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8206 Brake Light Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (1) near the support bracket on the lower steering column (3). 3. Disconnect the wire harness connector (5) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket (4). 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch. INSTALLATION CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket (4) on the lower steering column (3). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (1) is firmly Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8207 seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (5) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8211 Switch-Multifunction Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8212 Combination Switch: Description and Operation MULTIFUNCTION SWITCH The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (On and Off) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, low speed or high speed; and, an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch must be replaced as a unit. The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system Off. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the PCI data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned off, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the PCI data bus. The FCM energizes or de-energizes the selected low or high beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the right turn signal circuitry, and, downward to activate the left turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8213 cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. When a turn signal is activated, the multifunction switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the PCI data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the washer mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The FCM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the Off position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the FCM over the PCI data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for wiper system control. The multi-function switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8214 Combination Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. Multi-function Switch Tests 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the faulty multi-function switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8215 Combination Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8216 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. INSTALLATION 1. Slide the multi-function switch (1) into the multifunction switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8217 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.). 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clock-spring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 8224 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8228 Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8229 Left Instrument Panel Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8230 Switch-Headlamp Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8231 Headlamp Switch: Description and Operation The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (3) for exterior lighting control and a thumbwheel (2) for panel lamps dimming and interior lighting control. An optional switch has the same thumbwheel, but has an additional "Pull" function added to the rotary knob for selecting the optional front fog lamps. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and has a raised center lever to ease operator control. The thumbwheel is also plastic and knurled. The optional front fog lamp rotary knob is plastic with a smooth finish and an International Control and Display Symbol icon for "Front Fog Light" applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. The headlamp switch uses two resistor multiplexed outputs to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, and on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. - Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is pulled out to activate or pushed in to deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The FCM responds by energizing or de-energizing the front fog lamp relay in the Power Distribution Center (PDC). - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the FCM over the PCI data bus. The FCM responds by energizing or de-energizing the park lamp relay in the PDC and the high or low beam headlamp circuits. The FCM remembers which headlamp beams were last selected using the multi-function switch, and energizes those beams by default the next time the headlamps are turned On. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome defeat, dome on, parade/funeral mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the PCI data bus, and/or the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to and PWM processing of the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8232 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the left bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the instrument panel wire harness connector from the back of the headlamp switch. Headlamp Switch Tests 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the faulty headlamp switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8233 Headlamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch (4) and the left bezel (1) from the instrument panel (2) as a unit. 3. Disconnect the instrument panel wire harness connector (3) from the back of the headlamp switch. 4. Remove the three screws (3) that secure the headlamp switch (2) to the back of the instrument panel bezel (1). 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8234 1. Position the headlamp switch (2) to the back of the left instrument panel bezel (1). 2. Install and tighten the three screws (3) that secure the headlamp switch to the instrument panel bezel. Tighten the screws to 2 N.m (20 in.lbs.). 3. Position the left bezel (1) close enough to the instrument panel (2) to reconnect the instrument panel wire harness connector (3) to the back of the headlamp switch (4). 4. Reinstall the left bezel and the headlamp switch onto the instrument panel as a unit. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Switch-Horn Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 8238 Horn Switch: Description and Operation The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 8239 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Pick-Up Tail Light Bulb: Service and Repair Pick-Up REMOVAL NOTE: The rear lamp unit contains three bulbs: park/turn, park/brake/side marker, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. 3. Remove the four screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp unit. 5. Pull the base of the backup (1), park/brake/side marker (2), or park/turn (3) lamp bulb straight out of the appropriate socket in the socket plate (5). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The rear lamp unit contains three bulbs: park/turn, park/brake/side marker, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Pick-Up > Page 8245 1. Align the base of the backup (1), park/brake/side marker (2), or park/turn (3) lamp bulb with the appropriate socket in the socket plate (5). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber sealing washer (4) is properly installed and in good condition around the base of each bulb on the socket plate. 4. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 5. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 6. Install and tighten the four screws (3) that secure the socket plate to the housing. Tighten the screws to 1 N.m (12 in.lbs.). 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Pick-Up > Page 8246 Tail Light Bulb: Service and Repair Cab & Chassis REMOVAL NOTE: The rear lamp unit contains two bulbs: the park/turn/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn/ brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The rear lamp unit contains two bulbs: the park/turn/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup lamp bulb (4), or the park/turn/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Pick-Up > Page 8247 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 N.m (20 in.lbs.). 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Connector Views Trailer Lamps: Connector Views Wiring-Trailer Tow 4-Way Wiring-Trailer Tow 7-Way Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring Trailer Lamps: Description and Operation Trailer Tow Wiring In addition to the trailer tow wiring provisions, all vehicles include right and left trailer tow stop/turn relays installed in the PDC. When the FCM receives the appropriate inputs for normal turn signal, hazard warning or brake lamp operation, it responds by also energizing or de-energizing these trailer tow relays. When a trailer tow relay is energized, it provides battery voltage from a fused B(+) fuse to the trailer lamps through the trailer tow wiring to synchronize the illumination and flash rate of the trailer brake and turn signal lamps with those of the tow vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring > Page 8254 Trailer Lamps: Description and Operation Wiring-Trailer Tow The rear body wire harness on the rear frame (1) of all vehicles is equipped with a take out with a standard, light-duty 4-pin trailer tow connector (2) that is secured to the top of the trailer hitch platform (4) behind the rear bumper. Vehicles equipped with an optional factory-installed trailer towing package have a second take out with a connector (3) that plugs into a receptacle in the back of a heavy duty, sealed, 7-pin trailer tow connector that is located near the center of the rear bumper. Vehicles equipped with the trailer tow package also include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (1) that are stored in the glove box (2) when the vehicle is shipped from the factory. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The standard 4-pin trailer tow connector contains the following vehicle circuits: park/tail lamps, left stop/turn lamp, right stop/turn lamp, and ground. The optional trailer towing package 7-way connector contains the same circuits as the 4-pin connector plus the following additional circuits: backup lamp, trailer battery and electric brake. If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the truck battery while the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the vehicle glove box for Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring > Page 8255 type, location, and ampere rating of the fuse or circuit breaker. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Left Steering Column Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8260 Switch-Multifunction Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8261 Combination Switch: Description and Operation MULTIFUNCTION SWITCH The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (On and Off) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, low speed or high speed; and, an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch must be replaced as a unit. The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system Off. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the PCI data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned off, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the PCI data bus. The FCM energizes or de-energizes the selected low or high beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the right turn signal circuitry, and, downward to activate the left turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8262 cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. When a turn signal is activated, the multifunction switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the PCI data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the washer mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The FCM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the Off position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the FCM over the PCI data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for wiper system control. The multi-function switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8263 Combination Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. Multi-function Switch Tests 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the faulty multi-function switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8264 Combination Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8265 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. INSTALLATION 1. Slide the multi-function switch (1) into the multifunction switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8266 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.). 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clock-spring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation Turn Signal Cancel Cam: Description and Operation The turn signal cancel cam (3) is concealed within the steering column. The turn signal cancel cam consists of two lobes on a molded plastic ring that is snapped into the lower hub of the clockspring rotor. The clock-spring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring (2) is secured to the multi-function switch mounting housing on the steering column and remains stationary. The rotor of the clock-spring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If faulty or damaged, the entire clockspring unit must be replaced. When the multi-function switch control stalk is moved to a latched turn signal position, a turn signal cancel actuator is extended from the inside surface of the switch housing toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the two cam lobes will contact the actuator, automatically cancelling the turn signal event and releasing the latched multi-function switch control stalk to the neutral position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation Dodge Ram Trucks, 2004-2009 All, do not use a turn signal flasher relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster, between the speedometer and the tachometer. Each turn signal indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Turn Warning" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these icons from being clearly visible when they are not illuminated. A green Light Emitting Diode (LED) behind each cutout in the opaque layer of the overlay causes the icon to appear in green through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. The turn signal indicators give an indication to the vehicle operator that the turn signal (left or right indicator flashing) or hazard warning (both left and right indicators flashing) have been selected and are operating. These indicators are controlled by transistors on the instrument cluster electronic circuit board based upon the cluster programming, a hard wired multiplex input received by the cluster from the turn signal and hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, and electronic messages received from the Front Control Module (FCM) (also known as the Integrated Power Module/IPM) over the Programmable Communications Interface (PCI) data bus. Each turn signal indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, each LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the turn signal indicators for the following reasons: - Turn Signal-On Input - Each time the cluster detects a turn signal-on input from the turn signal switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic turn signal switch status messages to the FCM over the PCI data bus. The FCM responds to these messages by controlling a battery voltage output and the flash rate for either the right or left turn signal lamps. The FCM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right or left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional turn signal flasher. The turn signals and the turn signal indicators continue to flash on and off until the cluster receives a turn signal-off input from the multi-function switch, or until the ignition switch is turned to the Off position, whichever occurs first. - Hazard Warning-On Input - Each time the cluster detects a hazard warning-on input from the hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic hazard switch status messages to the FCM over the PCI data bus. The FCM responds to these messages by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps. The FCM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The turn signals and the turn signal indicators continue to flash on and off until the cluster receives a hazard warning-off input from the multi-function switch. - Lamp Out Mode - The instrument cluster also sends electronic turn signal on and off messages to the FCM over the PCI data bus, and the FCM flashes the appropriate exterior turn signal lamps. If the FCM detects an inoperative turn signal lamp or circuit, it increases the flash rate for the remaining operative turn signals and sends an electronic message back to the instrument cluster. The instrument cluster then increases the flash rate of the turn signal indicators) and the clicking rate of the electromechanical relay to provide an indication of the problem to the vehicle operator. - Actuator Test - Each time the cluster is put through the actuator test, the turn signal indicators will be turned on, then off again during the bulb check portion of the test to confirm the functionality of each LED and the cluster control circuitry. The instrument cluster continually monitors the multi-function switch and electronic messages from the FCM to determine the proper turn signal and hazard warning system control. For further diagnosis of the turn signal indicators or the instrument cluster circuitry that controls the indicators, refer to testing. For proper diagnosis of the turn signal and hazard warning system, the multi-function switch, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the turn signal indicators, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair REMOVAL NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (2) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8280 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb (2) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat bladed tool in the access slot between the underhood lamp housing (1) and the lamp lens (2). 3. Gently pry the lens until it unsnaps from the lamp housing. 4. Depress the bulb holder (2) inward far enough to disengage the terminals (3) of the bulb (1) and remove the bulb from the lamp housing (4). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair > Page 8285 1. Engage one of the terminals (3) of the bulb (1) over the bulb holder closest to the connector receptacle on the underhood lamp housing (4). 2. Depress the other bulb holder (2) inward far enough to engage the remaining bulb terminal. 3. Position the lens (2) over the lamp housing and use hand pressure to press the lens firmly and evenly onto the housing until it snaps into place. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams Vanity Lamp: Diagrams Lamp-Trinity-Left (Light Package) Lamp-Vanity-Right (Light Package) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 8289 Vanity Lamp: Service and Repair NOTE: Vehicles equipped with optional vanity lamps have a mirror with a lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat-bladed screwdriver on either side near the top or the bottom between the vanity lamp lens (2) and the lamp housing of the sun visor (1). 3. Carefully pry the lens outward until it unsnaps from the lamp housing. 4. Using small needle-nose pliers, carefully grasp the bulb (2) and pull the base out of the lamp socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 8290 1. Using small needle-nose pliers, carefully grasp the vanity lamp bulb (2) and align the base of the bulb with the socket in the lamp housing of the sun visor (1). 2. Push the bulb straight into the socket until the base is fully seated. 3. Insert one tab on the top or the bottom of the lens (2) into the appropriate slot at the top or bottom of the lamp housing. 4. Flex the lens far enough to engage the loose tab into its slot in the lamp housing. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8296 Heated Glass Element Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 8301 Rear Defogger Relay: Description and Operation The rear window defogger (EBL) relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The EBL relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the rear window defogger grid. The EBL relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The EBL relay is located in the IPM in the engine compartment. The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the EBL relay include: - Terminal (30) receives battery current through a fuse in the IPM only when the EBL relay coil is energized. - Terminal (85) receives a ground through the EBL relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (86) receives battery current through a fused ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the rear window defogger grid lines through the EBL relay only when the EBL relay coil is energized. - Terminal (87A) is not connected to any circuit in this application. The EBL relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 8302 Rear Defogger Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the EBL relay from the IPM. INSTALLATION 1. Position the EBL relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the EBL relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Switch > Component Information > Description and Operation Rear Defogger Switch: Description and Operation The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is activated, the timing circuit integral to the A/C-heater control operates the rear window defogger (EBL) relay and the heated mirror relay. When the relays are activated, current is directed to the rear window defogger and the outside rear view mirror grids. The grids heat the rear window and rear view mirror glass to help clear the surfaces of fog or frost. An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, it energizes the timing circuit integral to the A/C-heater control, which then activates the rear window defogger (EBL) relay and the heated mirror relay. The EBL relay controls the current flow to the grids of the rear window defogger. The EBL system will be on for approximately ten minutes or until the rear window defogger switch or the ignition switch is turned off. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8310 Heated Glass Element Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 8314 Rear Defogger Relay: Description and Operation The rear window defogger (EBL) relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The EBL relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the rear window defogger grid. The EBL relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The EBL relay is located in the IPM in the engine compartment. The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the EBL relay include: - Terminal (30) receives battery current through a fuse in the IPM only when the EBL relay coil is energized. - Terminal (85) receives a ground through the EBL relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (86) receives battery current through a fused ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the rear window defogger grid lines through the EBL relay only when the EBL relay coil is energized. - Terminal (87A) is not connected to any circuit in this application. The EBL relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 8315 Rear Defogger Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the EBL relay from the IPM. INSTALLATION 1. Position the EBL relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the EBL relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Defogger Switch > Component Information > Description and Operation Rear Defogger Switch: Description and Operation The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is activated, the timing circuit integral to the A/C-heater control operates the rear window defogger (EBL) relay and the heated mirror relay. When the relays are activated, current is directed to the rear window defogger and the outside rear view mirror grids. The grids heat the rear window and rear view mirror glass to help clear the surfaces of fog or frost. An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, it energizes the timing circuit integral to the A/C-heater control, which then activates the rear window defogger (EBL) relay and the heated mirror relay. The EBL relay controls the current flow to the grids of the rear window defogger. The EBL system will be on for approximately ten minutes or until the rear window defogger switch or the ignition switch is turned off. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8323 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8324 Left Rear Door (Right Side Similar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8325 Power Window Switch: Diagrams Switch-Power Window-Left Rear Switch-Power Window-Passenger Switch-Power Window-Right Rear Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8326 Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8327 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to testing. If not OK, replace the faulty switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Passenger Power Window Switch: Service and Repair Front Passenger REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Passenger > Page 8330 Power Window Switch: Service and Repair Rear Passenger REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams Circuit Breaker - Power Window Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations Power Window Motor: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 8338 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 8339 Left Rear Door (Right Side Similar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 8340 Power Window Motor: Diagrams Motor-Power Window-Driver Motor-Power Window-Left Rear Motor-Power Window-Passenger Motor-Power Window-Right Rear Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Left Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8344 Right Front Door Premium Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8345 Left Rear Door (Right Side Similar) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8346 Power Window Switch: Diagrams Switch-Power Window-Left Rear Switch-Power Window-Passenger Switch-Power Window-Right Rear Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8347 Switch-Window/Door Lock Driver C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8348 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to testing. If not OK, replace the faulty switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Passenger Power Window Switch: Service and Repair Front Passenger REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Passenger > Page 8351 Power Window Switch: Service and Repair Rear Passenger REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite Back Window Glass: Service and Repair Backlite BACKLITE REMOVAL CAUTION: It is difficult to salvage the backlite during the removal operation. The backlite is part of the structural support for the roof. The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface. Since the molding is set in urethane, it is unlikely it would be salvaged. Before removing the backlite, check the availability from the parts supplier. NOTE: The backlite is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the backlite. 1. Roll down door glass. 2. Remove headliner (9). 3. On standard cab models remove the upper b-pillar trim (5), Refer to Trim Panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 8357 4. On quad cab models remove the upper c-pillar trim (5), Refer to Trim Panel. 5. Bend backlite retaining tab (2) inward against glass. 6. Disconnect the rear window defogger electrical connector (if equipped). 7. Using a suitable pneumatic knife from inside the vehicle, cut urethane holding backlite frame to opening fence. 8. Separate glass (1) from vehicle. INSTALLATION 1. Clean urethane adhesive from around backlite opening fence. 2. If necessary, apply black-out primer to outer edge of replacement backlite frame (1). 3. If black-out primer was pre-applied on backlite, clean bonding surface with Isopropyl alcohol and clean lint free cloth. Allow 3 minutes for drying time. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 8358 4. Apply black-out primer to backlite opening fence. 5. Apply a 13 mm (0.5 in.) bead of urethane (4) around the perimeter of the window frame bonding surface (1). 6. Set glass (1) on lower fence and move glass forward into opening. 7. Firmly push glass (1) against rear window glass opening fence. 8. Bend tabs around edges of backlite opening fence to retain glass. 9. Clean excess urethane from exterior with MOPAR(R), Super Clean or equivalent. 10. Allow urethane to cure at least 24 hours (full cure is 72 hours). 11. Water test to verify repair before returning vehicle to service. 12. Connect the rear window defogger electrical connector, if equipped. 13. On standard cab models, install the upper b-pillar trim (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 8359 14. On quad cab models, install the upper c-pillar trim (5). 15. Install the headliner (9). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 8360 Back Window Glass: Service and Repair Backlite Vent Glass BACKLITE VENT GLASS REMOVAL 1. Slide the upper run channel (1) out of the window frame (2). 2. Slide the vent glass (3) upward to remove from the lower window frame (2). 3. Lower the glass (3) out of the upper window frame (2) and remove. INSTALLATION 1. Slide the vent glass (3) upper edge into window frame (2) and insert the lower edge into the lower molding. 2. Position the upper run channel (1) into the window frame (2) and slide it into place. 3. Verify vent glass (3) operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8366 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8367 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8368 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8369 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8370 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8371 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8372 2. Install the door trim panel (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8378 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8379 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8380 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8381 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8382 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8383 2. Install the door trim panel (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair Back Window Regulator: Service and Repair BACKLITE VENT GLASS-REGULATOR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel, Refer to Trim Panel. 4. Remove the two mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Separate the cable housings from the glass track (1). 7. Disconnect the cable ends from the vent glass (2). 8. Separate the support clips (5) and remove the regulator assembly (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 8388 1. Connect the cable ends to the vent glass (2). 2. Install the cable housings into the glass tracks (1). 3. Fasten the support clips (5). 4. Install the 2 mounting bolts (1). 5. Install the rear cab back panel. 6. Install the rear seats. 7. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 8393 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 8394 Front Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 8395 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 8396 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 8397 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures Manual REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (4) and the sight window (5) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8402 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N·m (89 in. lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Power REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8403 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (4) and the sight window (5) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8404 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8405 Rear Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8406 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8407 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 8408 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding . Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass Windshield: Customer Interest Body - Circular/Ring Marks on Glass NUMBER: 23-035-05 GROUP: Body DATE: July 26, 2005 SUBJECT: Circular/Ring Marks On Glass MODELS DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as "rings" or "circles" that won't clean off with standard glass cleaners. To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami(R)) or a glass polish containing Cerium Oxide. CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax(R), Comet(R), Soft-Scrub(R), etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass > Page 8417 PARTS REQUIRED CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass Windshield: All Technical Service Bulletins Body - Circular/Ring Marks on Glass NUMBER: 23-035-05 GROUP: Body DATE: July 26, 2005 SUBJECT: Circular/Ring Marks On Glass MODELS DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as "rings" or "circles" that won't clean off with standard glass cleaners. To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami(R)) or a glass polish containing Cerium Oxide. CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax(R), Comet(R), Soft-Scrub(R), etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass > Page 8423 PARTS REQUIRED CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8424 Windshield: Service Precautions WARNING WINDSHIELD SAFETY PRECAUTIONS Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. - Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. - DaimlerChrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warranty and will restore a vehicle to the requirements of fmvss 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. - Be sure to refer to the urethane manufacturer's directions for curing time specifications and do not use adhesive after its expiration date. - Vapors that are emitted from the urethane adhesive or primer could cause personal injury or death. Use them in a well-ventilated area. - Skin contact with urethane adhesive should be avoided. Personal injury or death may result. - Always wear eye and hand protection when working with glass. Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield . Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8425 Windshield: Service and Repair REMOVAL 1. Remove inside rear view mirror (3). 2. Remove cowl grille (2). 3. Remove the a-pillar weatherstrip retainer (1), Refer to Weatherstrip. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8426 4. Remove the a-pillar trim panels (2), Refer to Trim Panel. 5. Remove the headliner (9) and from the inside of the vehicle, cut the upper urethane bonding from around windshield upper edge using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 6. From the outside of the vehicle, cut urethane bonding from the remaining sides of the windshield using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 7. Separate windshield from vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8427 WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield. This is to avoid pressurizing the passenger compartment if a door is slammed before the urethane is cured. The potential for water leaks can result. The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. 1. Place replacement windshield (1) into windshield opening and position glass in the center of the opening against the support spacers (3). Mark the outside surface of the glass at the support spacers (3) with a grease pencil or pieces of masking tape and ink pen to use as a reference (2) for installation. Remove replacement windshield from windshield opening. 2. Position the windshield (1) inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. By 4 in. By 20 in.) blocks (3), placed parallel 75 cm (2.5 ft.) apart. 3. Clean inside of windshield with MOPAR(R) Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint-free cloth. 5. Apply black-out primer onto the glass using the windshield molding as a guide. The primer should be 15 mm (5/8 in.) wide on the top and sides of the glass and 25 mm (1 in.) on the bottom of windshield. Allow at least three minutes drying time. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8428 6. Locate NEW support spacers (3) on support brackets and adjust to lowest height. 7. Position seven new foam spacers (4 and 3) on the inside surface of the windshield, flush with the lower and side edges. 8. Position three new foam spacers (1) on the inside surface of the windshield, at a minimum distance of 3 mm (0.12 in.) from the top edge of the windshield. 9. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8429 10. Apply a 13 mm (1/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of windshield (2). At the top, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the other three sides apply the bead 14 mm (0.55 in.) inboard from the glass edge. 11. Install the a-pillar trim (2). 12. With the aid of a helper, position the windshield (2) over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers (3). 13. Slowly lower windshield glass (2) to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass (2) onto fence along the A-Pillars. Push windshield (2) inward to the fence at the bottom corners. 14. Push windshield (2) upward, setting the windshield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12 in.) and ratchet up the adjustable support Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 8430 brackets. 15. Using clean water, lightly mist the support spacers (3). 16. Clean excess urethane from exterior with MOPAR(R) Super Clean or equivalent. 17. Install cowl grille (2). 18. Install rear view mirror support bracket (4). 19. Install rear view mirror (3). 20. Install the a-pillar weatherstrip retainer (1). 21. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation Check Valve: Description and Operation A single washer system check valve is standard equipment on this model, and is installed in the washer system plumbing. The check valve is integral to the washer nozzle plumbing eye fitting (2) located in the cowl plenum area beneath the cowl plenum cover/grille panel near the base of the windshield. The check valve consists of a molded plastic body with a raised arrowhead (4) molded into its center section that indicates the direction of the flow through the valve, and three barbed hose nipples (1 and 3) formed in a eye configuration on the outside circumference of the center section of the valve body. The check valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The check valve provides more than one function in this application. It serves as a eye connector fitting between the engine compartment and washer nozzle sections of the washer supply hose. It prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay from when the washer switch is actuated until washer fluid was dispensed through the washer nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned Off. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure (5) unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied to a piston (2) by a spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the two washer nozzles (4). When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. The check valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Page 8435 Check Valve: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (5), disconnect the cowl plenum (4) and washer nozzle (1 and 6) hoses from the three barbed nipples of the check valve (2). 5. Remove the check valve from the underside of the cowl plenum cover/grille panel. INSTALLATION 1. Position the check valve (2) to the underside of the cowl plenum cover/grille panel (5). Be certain that the flow direction arrow molded into the check valve body is oriented towards the washer nozzles. 2. From the underside of the cowl plenum cover/grille panel, reconnect the cowl plenum (4) and washer nozzle (1 and 6) hoses to the three barbed nipples of the check valve. 3. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 4. Close and latch the hood. 5. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 8440 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay Wiper Relay: Description and Operation Wiper High/Low Relay The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay > Page 8446 Wiper Relay: Description and Operation Wiper On/Off Relay The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper on/off relay. The most reliable, efficient, and accurate means to diagnose the wiper on/off relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper on/off relay operation requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8451 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8452 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8453 Sensor-Washer Fluid Level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8454 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the side of the washer reservoir (4) in the engine compartment. Only the molded plastic switch mounting flange (1) and the integral connector receptacle (8) are visible when the switch is installed in the reservoir. A short nipple formation (2) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal (5) installed in the mounting hole of the reservoir. A small, molded plastic float (3) has two pivot pins (6) near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the nipple formation. A small magnet (7) is secured within the end of the float nearest the nipple, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8455 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch (3) from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch (3) through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8456 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation A washer fluid indicator is standard equipment on all instrument clusters. The washer fluid indicator consists of the text "LOW WASH", which appears in the lower portion of the odometer Vacuum-Fluorescent Display (VFD) unit. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The "LOW WASH" text appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the VFD in the instrument cluster. The washer fluid indicator gives an indication to the vehicle operator that the fluid level in the washer reservoir is low. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) (also known as the Integrated Power Module/IPM or Power Distribution Center/PDC) over the Programmable Communications Interface (PCI) data bus. The washer fluid indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the washer fluid indicator for the following reasons: - Washer Fluid Indicator Lamp-On Message - Each time the cluster receives a washer fluid indicator lamp-on message from the FCM indicating that a low washer condition has been detected for sixty consecutive seconds, the washer fluid indicator is illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a washer fluid indicator lamp-off message for sixty consecutive seconds from the FCM or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the washer fluid indicator is cycled off and then on again by the appropriate washer fluid lamp messages from the FCM. - Actuator Test - Each time the cluster is put through the actuator test, the washer fluid indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM continually monitors the washer fluid level switch in the washer reservoir to determine the level of the washer fluid. The FCM then sends the proper washer fluid indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the washer fluid indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the washer fluid level switch, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the washer fluid indicator, a diagnostic scan tool is required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Left Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8463 Left Front Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8464 Integrated Power Module And Fan Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8465 Sensor-Washer Fluid Level Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8466 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the side of the washer reservoir (4) in the engine compartment. Only the molded plastic switch mounting flange (1) and the integral connector receptacle (8) are visible when the switch is installed in the reservoir. A short nipple formation (2) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal (5) installed in the mounting hole of the reservoir. A small, molded plastic float (3) has two pivot pins (6) near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the nipple formation. A small magnet (7) is secured within the end of the float nearest the nipple, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8467 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch (3) from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch (3) through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 8468 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation Windshield Washer Hose: Description and Operation The washer plumbing consists of a small diameter rubber reservoir washer hose that is routed from the barbed outlet nipple of the electric washer pump/motor unit on the washer reservoir through a trough molded into the back of the reservoir above the washer pump to the engine compartment washer hose to the right side of the engine cooling module. On SRT-10 models or those equipped with an optional diesel engine, the reservoir washer hose is routed through routing clips on the top of the radiator fan shroud from the washer reservoir on the left side of the radiator to the engine compartment washer hose on the right side of the radiator. The engine compartment washer hose is contained within the right headlamp and dash wire harness (2), which is routed through the engine compartment along the top of the right front fender wheel house to the dash panel. This hose is connected to the washer reservoir washer hose at one end (5) and to the cowl plenum washer hose at the other end (3) with molded plastic in-line fittings that have a barbed nipple on each end. The cowl plenum washer hose (4) is routed from the engine compartment into the cowl plenum area through a trough formation located near the right end of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to the washer system check valve/eye fitting on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose and the two washer nozzle hoses are routed through integral routing clips on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to one nipple on the eye fitting and the two washer nozzle hoses are connected to the other two nipples. The washer nozzle hoses are then routed along the underside of the cowl plenum cover/grille panel to the two washer nozzles. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are faulty or damaged, they must be replaced. Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor through the washer system plumbing and fittings to the two washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Pump-Washer-Windshield Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 8475 Windshield Washer Pump: Description and Operation The washer pump/motor unit (1) is located on the rearward facing surface of the washer reservoir, in the right (except SRT-10 and diesel) or left (SRT-10 and diesel only) front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a barbed inlet nipple (6) on the pump housing passes through a rubber grommet seal installed in a dedicated mounting hole of the washer reservoir. A removable molded plastic filter screen (7) inserted into the inlet nipple prevents most debris from entering the pump housing. When the pump is installed in the reservoir a barbed outlet nipple (5) on the pump housing connects the unit to the washer system through a short washer reservoir hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap post (2) on the motor housing and a snap post receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (3) on the top of the motor housing connects the unit to the vehicle electrical system. The washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The washer pump/motor unit features a small Direct Current (DC) electric motor. The motor is connected to the vehicle electrical system through a single take out and two-cavity connector of the right (except SRT-10 and diesel) or left (SRT-10 and diesel only) headlamp and dash wire harness. The motor is grounded at all times through another take out of the right (except SRT-10 and diesel) or left (SRT-10 and diesel only) headlamp and dash wire harness. On models except SRT-10 or diesel, a single eyelet terminal connector is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. On SRT-10 or diesel models, an eyelet terminal connector is secured by a ground screw to the left front fender inner shield in the engine compartment. The motor receives battery current on a washer pump/motor control circuit. The washer pump/motor control circuit is energized through a high side driver within the Front Control Module (FCM) whenever the FCM receives an electronic message requesting washer system operation from the ElectroMechanical Instrument Cluster (EMIC) over the Programmable Communications Interface (PCI) data bus. The EMIC monitors a resistor multiplexed hard wired input from the momentary washer switch contacts within the multi-function switch on the steering column to determine when it should issue the electronic message requesting washer system operation. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the motor spins the rotor within the washer pump. The spinning pump rotor pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass. The washer pump/motor unit may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the FCM, the PCI data bus or the electronic messages used to control the operation of the washer pump/motor unit. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit, the EMIC, the FCM, the PCI data bus, and the electronic messages for washer pump/motor unit control requires the use of a diagnostic scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 8476 Windshield Washer Pump: Service and Repair REMOVAL NOTE: The washer pump/motor unit can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose from the barbed outlet nipple (8) of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the right headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle (1). 5. Firmly grasp the top of the washer pump/motor housing. 6. Pull lightly outward on the top of the washer pump/ motor housing away from the washer reservoir (6) far enough to disengage the snap post (2) on the top of the motor from the receptacle (1) in the reservoir. 7. Pull the washer pump/motor unit straight out from the washer reservoir far enough to disengage the barbed pump inlet nipple (7) from the rubber grommet seal (4) in the reservoir. 8. Remove the washer pump/motor unit from behind the washer reservoir. 9. Remove the rubber grommet seal from the washer reservoir and discard. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 8477 1. Install a new rubber grommet seal (4) into the washer pump mounting hole in the washer reservoir (6). Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple (7) of the washer pump to the rubber grommet seal in the washer reservoir. 3. Using hand pressure, press on the washer pump/ motor unit firmly and evenly until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Align the washer pump/motor snap post (2) on the top of the motor housing with the snap post receptacle (3) in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the snap post snaps into the washer reservoir receptacle. 6. Reconnect the washer reservoir hose to the barbed outlet nipple (8) of the washer pump. 7. Reconnect the right headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle (1). 8. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 9. Reconnect the battery negative cable. 10. Close and latch the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation Windshield Washer Reservoir: Description and Operation Except on SRT-10 and diesel models, the molded plastic washer fluid reservoir (1) is integral to the engine coolant overflow bottle (4) located on the right rearward facing surface of the engine cooling module shroud in the right front corner of the engine compartment. On SRT-10 and diesel models, the molded plastic washer fluid reservoir is separate from the engine coolant overflow bottle and is mounted on the rearward facing surface of the left vertical member of the radiator support in the engine compartment. These reservoirs are constructed of a translucent plastic that allows the fluid level to be inspected without removing the reservoir caps. A round bright yellow plastic cap (2) with a rubber seal snaps over the open end of the washer reservoir filler neck and can be easily distinguished from the coolant overflow bottle cap (3) by an International Control and Display Symbol icon for "Windshield Washer" and the text "Washer Fluid Only" molded into it. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just behind the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. Except on SRT-10 and diesel models, the washer reservoir is secured to the cooling module radiator shroud with two integral tabs at the bottom, and through two integral mounting brackets with two screws at the top. The two bottom tabs are inserted into two slots near the bottom of the shroud, while the two screws secure the mounting brackets to integral mounting points near the top of the shroud. On SRT-10 and diesel models, the washer reservoir is secured with two screws through integral mounting brackets to the left vertical member of the radiator support. There are separate, dedicated holes on the lower rearward facing side of either reservoir provided for the mounting of the washer/pump motor unit (6) and the washer fluid level switch (5). A snap post receptacle for the washer pump and a routing trough for the washer hose are molded into both reservoirs to allow for mounting of the washer pump/ motor unit without the use of fasteners. Except on SRT-10 and diesel models, the washer reservoir is serviced only as a unit with the engine coolant reserve bottle. A washer reservoir cannot be repaired and, if faulty or damaged, the unit must be replaced. The washer pump/motor unit, the washer fluid level switch, their rubber grommet seals, as well as the reservoir filler cap are each available for individual service replacement. The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted just above the washer pump inlet nipple in the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer system will no longer operate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 8481 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the coolant overflow hose (3) from the nipple on the radiator filler neck. It is not necessary to open or drain the engine cooling system. 4. Disconnect the reservoir washer hose (4) from the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir into a clean container for reuse. 5. Disconnect the right headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle (5). 6. Disconnect the right headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle (7). 7. Remove the two screws (2) that secure the reservoir mounting brackets to the top of the radiator shroud. 8. Grasp the bottom of the washer reservoir (1) firmly with both hands and pull the unit sharply upward to disengage the locking feature on the washer reservoir from the depression in the radiator shroud. 9. Continue lifting the washer reservoir upward far enough to disengage the two mounting tabs at the bottom from the two slots (6) at the bottom of the radiator shroud. 10. Remove the washer reservoir from the right side of the engine compartment. INSTALLATION 1. Position the washer reservoir (1) into the right side of the engine compartment. 2. Align and insert the two mounting tabs at the bottom of the reservoir into the two slots (6) at the bottom of the radiator shroud. 3. Place both hands on the top of the washer reservoir and push the unit downward far enough for the locking feature on the washer reservoir to snap into the depression in the radiator shroud. 4. Install and tighten the two screws (2) that secure the mounting brackets at the top of the reservoir to the mounting provisions at the top of the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 8482 radiator shroud. Tighten the screws to 7 N.m (60 in.lbs.). 5. Reconnect the right headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle (7). 6. Reconnect the right headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle (5). 7. Reconnect the reservoir washer hose (4) to the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness. 8. Reconnect the coolant overflow hose (3) to the nipple on the radiator filler neck. 9. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 10. Reconnect the battery negative cable. 11. Check and adjust the coolant level in the coolant overflow bottle as necessary. 12. Close and latch the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation The fluidic washer nozzles (1) are constructed of molded plastic. Each nozzle has two integral latches (2) and an anti-rotation tab (4) that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice (5) is oriented towards the windshield glass. The washer plumbing fittings (3) for the washer nozzles extend below the cowl plenum cover/grille panel. The cowl plenum cover/grille panel must be removed from the vehicle to access the nozzles for service. The washer nozzles cannot be adjusted or repaired. If faulty or damaged, they must be replaced. The two washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/ motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 8486 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (1), disconnect the washer nozzle hose from the barbed nipple (3) of the washer nozzle. 5. From the underside of the cowl plenum cover/grille panel, release the integral latch features (2) of the washer nozzle and push the nozzle out through the mounting hole toward the top side of the cowl plenum cover/grille panel. 6. Remove the washer nozzle from the top of the cowl plenum cover/grille panel. INSTALLATION 1. From the top of the cowl plenum cover/grille panel, position the nipple end of the washer nozzle through the mounting hole and engage the anti-rotation tabs (2 and 4) of the nozzle into the anti-rotation notches in the mounting hole. 2. Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral latch features (6) lock into place on the underside of the cowl plenum cover/grille panel (1). 3. From the underside of the cowl plenum cover/grille panel, reconnect the washer hose to the barbed nipple (3) of the washer nozzle. 4. Reinstall the washer nozzle hose into its routing clips on the underside of the cowl plenum cover/ grille panel. 5. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 6. Close and latch the hood. 7. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation Wiper Arm: Description and Operation The wiper arms are the rigid members located between the wiper pivots protruding from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arms each have a die cast metal pivot end (3) with a large internally serrated socket formation at one end. A key (4) within the socket formation indexes the wiper arm to a keyway in the pivot shaft to provide wiper alignment, and a spring-loaded latch (5) on the underside of the pivot end locks the unit to the pivot shaft when it is fully installed. The right and left wiper arms for this model are not interchangeable, as the right wiper arm is slightly longer than the left one. The wide end of a tapered, stamped steel channel (8) hinges on and is secured with a hinge pin (6) to the blade end of both the right and left wiper arm pivot ends. One end of a long, rigid, stamped steel strap (2), with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook (1). Concealed within the stamped steel channel, one end of a long spring (7) is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced. The wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The serrated and keyed socket formation in the wiper arm pivot end interlocks with the serrations and keyway on the outer circumference of the wiper pivot shaft, providing positive engagement and alignment of this connection. The latch positively locks the wiper arm to the wiper pivot shaft when the arm is fully installed. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 8490 Wiper Arm: Service and Repair REMOVAL 1. Lift the wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot shaft connection. 2. Pull the latch (2) on the pivot end (1) of the wiper arm outward. 3. Using a slight rocking action, disengage and remove the wiper arm pivot end from the wiper pivot shaft. INSTALLATION NOTE: The right and left wiper arms are not interchangeable. The right wiper arm is slightly longer than the left. Be certain that each wiper arm is installed on the proper wiper pivot. 1. Place the wiper arm hinge in its over-center position prior to attempting installation. 2. The wiper arms are indexed to the wiper pivot shafts with integral keys in the wiper arm pivot ends (1) and keyways in the wiper pivot shafts. Align the key of the wiper arm to the keyway on the wiper pivot shaft. 3. Once the wiper blade is aligned, push the pivot of the wiper arm down firmly and evenly over the wiper pivot shaft until it is fully engaged. When the wiper arm is fully engaged on the wiper pivot, the spring-loaded latch (2) will snap back into place against the wiper arm pivot end. 4. Gently lower the wiper arm until the wiper blade is in position on the windshield glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 8504 Wiper Blade: Description and Operation Each wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws (6) of the superstructure. All models have two 60.00 centimeter (23.62 inch) long wiper blades with non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 8505 Wiper Blade: Service and Repair REMOVAL CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. INSTALLATION CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Left Rear Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 8509 Left Side Engine Compartment Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement Technical Service Bulletin # J11 Date: 090821 Recall - Windshield Wiper Motor Replacement August 2009 Dealer Service Instructions for: Safety Recall J11 Mopar Windshield Wiper Motor Models 2002-2008 (DR) Dodge Truck (1500 series pickup) 2005-2009 (DH) Dodge Truck (2500 series pickup) 2006-2009 (D1) Dodge Truck (3500 series pickup) 2007-2008 (DC) Dodge Truck (3500 series cab chassis) 2008 (DM) Dodge Truck (4500/5500 series cab chassis) NOTE: This recall applies only to the above vehicles that had the original windshield wiper motor replaced with a Mopar service parts windshield wiper motor. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts windshield wiper motor may have been installed on about 1,000 of the above vehicles. These replacement wiper motors may fail under certain operating conditions. A loss of windshield wipers could limit the driver's visibility and cause a crash without warning. Repair The windshield wiper motor must be inspected. Vehicles equipped with a Mopar service parts windshield wiper motor must have the motor replaced. Parts Information Special Tools No special tools are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8518 Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Remove the right and left wiper arms from the wiper pivots. 2. Open the hood. 3. Disconnect and isolate the negative battery cable(s). 4. Remove the plenum cover sound deadening pad. 5. Remove the plastic cowl plenum cover panel from the cowl plenum to expose the wiper motor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8519 6. Inspect the windshield wiper motor: > If the wiper motor has two rubber mounting bushings (Figure 1), the wiper motor is original and is not involved in this recall. Continue with Step 21 of this procedure. NOTE: If the original wiper motor requires some type of repair, the repair cost is the responsibility of the vehicle owner. > If the windshield wiper motor has one rubber mounting bushing (Figure 2), the wiper motor is a Mopar replacement motor and is involved in this recall. Continue with Step 7 of this procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8520 7. Disconnect the wiper motor electrical connector (Figure 3). 8. Remove the wiper motor linkage arm retaining nut from the wiper motor shaft (Figure 3). 9. Remove the wiper motor linkage arm from the motor shaft. NOTE: Do not disconnect the wiper motor linkage arm from the remaining wiper linkage. 10. Remove the three wiper motor retaining bolts (Figure 4). 11. Remove the wiper motor from the vehicle. 12. Transfer the rubber isolator from the old wiper motor onto the new wiper motor (Figure 4). 13. Discard the old wiper motor. 14. Place the new wiper motor into position. 15. Install the three wiper motor retaining bolts (Figure 4). 16. Tighten the upper wiper motor retaining bolts to 70 in. lbs. (8 N.m). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8521 17. Tighten the lower mounting bolt to 75 in. lbs. (8.5 N.m). 18. Connect the wiper motor electrical connector (Figure 3). 19. Install the wiper motor linkage arm to the wiper motor shaft as shown in Figure 5. NOTE: The arms for the wiper pivots must be pointing downward (forward). 20. Install the wiper motor linkage arm nut and tighten the nut to 204 in.lbs. (23 N.m). 21. Install the plastic cowl plenum cover panel. 22. Install the plenum cover sound deadening pad. 23. Connect the negative battery cable(s) to the negative battery post(s). 24. Close the hood. 25. Install the right and left wiper arms onto the wiper pivots and verify that the wiper arm retaining clips are engaged. 26. Cycle the windshield wipers to verify proper operation and the wiper blade park position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8522 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement Technical Service Bulletin # J11 Date: 090821 Recall - Windshield Wiper Motor Replacement August 2009 Dealer Service Instructions for: Safety Recall J11 Mopar Windshield Wiper Motor Models 2002-2008 (DR) Dodge Truck (1500 series pickup) 2005-2009 (DH) Dodge Truck (2500 series pickup) 2006-2009 (D1) Dodge Truck (3500 series pickup) 2007-2008 (DC) Dodge Truck (3500 series cab chassis) 2008 (DM) Dodge Truck (4500/5500 series cab chassis) NOTE: This recall applies only to the above vehicles that had the original windshield wiper motor replaced with a Mopar service parts windshield wiper motor. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts windshield wiper motor may have been installed on about 1,000 of the above vehicles. These replacement wiper motors may fail under certain operating conditions. A loss of windshield wipers could limit the driver's visibility and cause a crash without warning. Repair The windshield wiper motor must be inspected. Vehicles equipped with a Mopar service parts windshield wiper motor must have the motor replaced. Parts Information Special Tools No special tools are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8528 Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Remove the right and left wiper arms from the wiper pivots. 2. Open the hood. 3. Disconnect and isolate the negative battery cable(s). 4. Remove the plenum cover sound deadening pad. 5. Remove the plastic cowl plenum cover panel from the cowl plenum to expose the wiper motor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8529 6. Inspect the windshield wiper motor: > If the wiper motor has two rubber mounting bushings (Figure 1), the wiper motor is original and is not involved in this recall. Continue with Step 21 of this procedure. NOTE: If the original wiper motor requires some type of repair, the repair cost is the responsibility of the vehicle owner. > If the windshield wiper motor has one rubber mounting bushing (Figure 2), the wiper motor is a Mopar replacement motor and is involved in this recall. Continue with Step 7 of this procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8530 7. Disconnect the wiper motor electrical connector (Figure 3). 8. Remove the wiper motor linkage arm retaining nut from the wiper motor shaft (Figure 3). 9. Remove the wiper motor linkage arm from the motor shaft. NOTE: Do not disconnect the wiper motor linkage arm from the remaining wiper linkage. 10. Remove the three wiper motor retaining bolts (Figure 4). 11. Remove the wiper motor from the vehicle. 12. Transfer the rubber isolator from the old wiper motor onto the new wiper motor (Figure 4). 13. Discard the old wiper motor. 14. Place the new wiper motor into position. 15. Install the three wiper motor retaining bolts (Figure 4). 16. Tighten the upper wiper motor retaining bolts to 70 in. lbs. (8 N.m). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8531 17. Tighten the lower mounting bolt to 75 in. lbs. (8.5 N.m). 18. Connect the wiper motor electrical connector (Figure 3). 19. Install the wiper motor linkage arm to the wiper motor shaft as shown in Figure 5. NOTE: The arms for the wiper pivots must be pointing downward (forward). 20. Install the wiper motor linkage arm nut and tighten the nut to 204 in.lbs. (23 N.m). 21. Install the plastic cowl plenum cover panel. 22. Install the plenum cover sound deadening pad. 23. Connect the negative battery cable(s) to the negative battery post(s). 24. Close the hood. 25. Install the right and left wiper arms onto the wiper pivots and verify that the wiper arm retaining clips are engaged. 26. Cycle the windshield wipers to verify proper operation and the wiper blade park position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 8532 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Motor-Windshield Wiper Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8535 Wiper Motor: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. Linkage (2) - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots (2) - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8536 Wiper Motor: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8537 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in.lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in.lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation Wiper Motor Linkage: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. Linkage (2) - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots (2) - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 8541 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 8542 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in.lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in.lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. Linkage (2) - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots (2) - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 8546 Wiper Pivot: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 8547 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in.lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in.lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.7L VIN D (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay Wiper Relay: Description and Operation Wiper High/Low Relay The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a diagnostic scan tool.